2-Stage Mast: Maintenance

Maintenance
2-STAGE MAST
PART NO. 550088524 4000 YRM 1647

SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Yale® dealer.
Service Manuals provide general guidelines for maintenance and service and are intended for use by
trained and experienced technicians. Failure to properly maintain equipment or to follow instructions con-
tained in the Service Manual could result in damage to the products, personal injury, property damage or
death.
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and that the
load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to support the
weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT TRUCK
ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed the
specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to re-
move parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are flammable.
Be sure to follow the necessary safety precautions when handling these fuels and when working on these
fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the area.
Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this man-
ual:
WARNING
Indicates a hazardous situation which, if not avoided, could result in death
or serious injury.
CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.
On the lift truck, the WARNING symbol and word are on orange back-
ground. The CAUTION symbol and word are on yellow background.
Table of Contents
TABLE OF CONTENTS
Series Code / Model Designation Reference Table ..................................................................................................1
General ..................................................................................................................................................................... 1
Description And Operation ........................................................................................................................................1
Mast System .........................................................................................................................................................1
Tilting .................................................................................................................................................................... 1
Lifting .................................................................................................................................................................... 2
Operation ......................................................................................................................................................... 2
Pilot Operated Check Valves ........................................................................................................................... 3
Gland Lubrication ............................................................................................................................................. 4
Emergency Lowering Valve ............................................................................................................................. 4
Operation ..................................................................................................................................................... 4
Lift Chains ........................................................................................................................................................ 5
Elongation Through Wear ............................................................................................................................5
Speed of Wear .............................................................................................................................................5
Plate Height Wear ........................................................................................................................................6
Lubrication ................................................................................................................................................... 6
Restoring The Oil Film ................................................................................................................................. 6
Maintenance ................................................................................................................................................ 6
Maintaining The Presence of Oil ..................................................................................................................7
Corrosion Protection .................................................................................................................................... 7
Requirements for Chain Lubricant ............................................................................................................... 7
Load Rollers ..................................................................................................................................................... 8
Bearing Blocks ................................................................................................................................................. 8
Carriage ................................................................................................................................................................9
Standard Carriage with Manual Fork Positioning .............................................................................................9
Standard Carriage with Hydraulic Fork Positioning ..........................................................................................9
Dual Function Side Shift and Fork Positioning (DFSSFP) Carriage .............................................................. 10
Integral Side Shift ...........................................................................................................................................10
Carriage Valve ............................................................................................................................................... 11
Alternating Pressure and Tank (P & T) ...................................................................................................... 11
Fixed Pressure and Tank (P & T) .............................................................................................................. 11
Flow Divider for Simultaneous Fork Positioning .............................................................................................11
Valve for Dual Function with Side Shift and Fork Positioning (DFSSFP) .......................................................13
Fixed Pressure and Tank System (Fixed P & T) ............................................................................................15
Forks .............................................................................................................................................................. 17
Safety Procedures When Working Near Mast ....................................................................................................18
Before Starting Repairs to the Hydraulic System, Always: .................................................................................19
Remove and Replace ............................................................................................................................................. 19
Forks ...................................................................................................................................................................19
Remove ..........................................................................................................................................................19
Install ..............................................................................................................................................................20
Fork Guide And Fork Pin .................................................................................................................................... 21
Remove ..........................................................................................................................................................21
Install ..............................................................................................................................................................21
Carriage ..............................................................................................................................................................22
Remove ......................................................................................................................................................22
Install ..........................................................................................................................................................23
Carriage Bearing Blocks ................................................................................................................................ 24
Remove ......................................................................................................................................................24
Install ..........................................................................................................................................................25
©2016 Yale Materials Handling Corp. i

Table of Contents
TABLE OF CONTENTS (Continued)

Carriage Load Rollers .................................................................................................................................... 25
Replace ......................................................................................................................................................25
Side Shift Cylinder ..........................................................................................................................................27
Remove ......................................................................................................................................................27
Disassemble .............................................................................................................................................. 27
Clean And Inspect ......................................................................................................................................28
Assemble ................................................................................................................................................... 28
Install ..........................................................................................................................................................29
Fork Positioner Cylinder .................................................................................................................................29
Remove ......................................................................................................................................................29
Disassemble .............................................................................................................................................. 30
Clean and Inspect ......................................................................................................................................30
Assemble ................................................................................................................................................... 31
Install ..........................................................................................................................................................31
Carriage Valves ..............................................................................................................................................31
Remove ......................................................................................................................................................31
Install ..........................................................................................................................................................32
Valve for Fixed P & T Systems ...................................................................................................................... 32
Remove and Disassemble .........................................................................................................................32
Clean and Inspect ......................................................................................................................................34
Assemble and Install ..................................................................................................................................34
Flow Divider for Simultaneous Fork Positioning Valve ...................................................................................35
Restrictor Valve and Relief Valve Replacement ........................................................................................ 35
Dual Function Valve for Side Shifting and Fork Positioning ...........................................................................35
Solenoid Valve Replacement .....................................................................................................................35
Relief Valve Replacement ..............................................................................................................................36
Remove ......................................................................................................................................................36
Install ..........................................................................................................................................................36
Mast ....................................................................................................................................................................36
Lift Chains and Top Chain Anchor ................................................................................................................. 36
Remove ......................................................................................................................................................36
Install ..........................................................................................................................................................36
Chain Anchor On Carriage .............................................................................................................................37
Remove ......................................................................................................................................................37
Install ..........................................................................................................................................................37
Chain Sheave .................................................................................................................................................38
Remove ......................................................................................................................................................38
Install ..........................................................................................................................................................38
Header Hoses ................................................................................................................................................ 39
Remove ......................................................................................................................................................39
Install ..........................................................................................................................................................41
Electric Mast Cable ........................................................................................................................................ 41
Remove ......................................................................................................................................................41
Install ..........................................................................................................................................................41
Hose Sheave ..................................................................................................................................................42
Remove and Disassemble .........................................................................................................................42
Assemble and Install ..................................................................................................................................42
Mast Assembly ...............................................................................................................................................43
Remove ......................................................................................................................................................43
Disassemble .............................................................................................................................................. 45
ii
Table of Contents

Assemble ................................................................................................................................................... 46
Install ..........................................................................................................................................................47
Inner Mast Load Rollers ................................................................................................................................. 49
Replace ......................................................................................................................................................49
Mast Bearing Blocks ...................................................................................................................................... 50
Remove ......................................................................................................................................................50
Install ..........................................................................................................................................................50
Lift Cylinders .......................................................................................................................................................51
Remove ..........................................................................................................................................................51
Disassemble ...................................................................................................................................................54
Clean and Inspect .......................................................................................................................................... 54
Assemble ....................................................................................................................................................... 54
Install ..............................................................................................................................................................55
Tilt Cylinders .......................................................................................................................................................56
Remove ..........................................................................................................................................................56
Disassemble ...................................................................................................................................................57
Clean and Inspect .......................................................................................................................................... 57
Assemble ....................................................................................................................................................... 57
Install ..............................................................................................................................................................58
Checks and Adjustments ........................................................................................................................................ 59
General Checks ..................................................................................................................................................59
Mast Condition Check .................................................................................................................................... 59
Mast Operation Check ................................................................................................................................... 60
Counterbalance Valve Check (for Only) E876 and E877................................................................................60
Fork Inspection and Adjustment .....................................................................................................................60
Lift Chain Inspection .......................................................................................................................................61
Lift Chain Lubricant Requirements .................................................................................................................62
Lift Chain Lubrication Procedure ....................................................................................................................62
Leak Checks .................................................................................................................................................. 62
Mast Vertical Creep ................................................................................................................................... 62
Mast Tilt Drift ..............................................................................................................................................63
Adjustments ........................................................................................................................................................63
Lift Cylinder Shimming ................................................................................................................................... 63
Lift Chain and Fork Height Adjustment .......................................................................................................... 65
Header Hose Tension Adjustment ................................................................................................................. 67
Electric Mast Cable Tension Adjustment ....................................................................................................... 67
Counterbalance Valve Adjustment .................................................................................................................67
Tilt Cylinder Backward Tilt Angle Adjustment ................................................................................................ 68
Mast Support Pad Adjustment ....................................................................................................................... 68
Troubleshooting ...................................................................................................................................................... 69
Introduction .........................................................................................................................................................69
No Hydraulic Movement With Engine Running .................................................................................................. 69
Initial Basic Check ..........................................................................................................................................69
Electrical Supply .............................................................................................................................................70
Hydraulic Supply ............................................................................................................................................ 70
Fault Code ......................................................................................................................................................70
No Lowering Possible with Engine OFF ............................................................................................................. 71
Incorrect Movement ............................................................................................................................................71
Irregular (shaking) Movement or Slight Carriage Movement When Starting Engine ..................................... 71
Unequal Movement of Left And Right Tilt Cylinder ........................................................................................ 71
iii
Table of Contents

Insufficient Lifting Speed ................................................................................................................................ 71
Insufficient Lifting Capacity ............................................................................................................................ 72
Incorrect Lowering Speed .............................................................................................................................. 72
Lift Cylinder Creep ......................................................................................................................................... 72
Tilt Cylinder Creep ......................................................................................................................................... 72
This section is for the following models:
iv
4000 YRM 1647 Series Code / Model Designation Reference Table
Series Code / Model Designation Reference Table

This section is for the following models:
Series Code European Model Americas Model

D876 GDP/GLP80-120DB GP/GDP/GLP170-280DB
D877 GDP/GLP130-160EB GP/GDP/GLP300-360EB
E876 GDP80DC, GDP90DC, GDP100DC, GDP190DC, GDP210DC, GDP230DC,
GDP100DCS, GDP120DC GDP230DCS, GDP250DC, GDP280DC)
E877 GDP130EC, GDP140EC, GDP160EC GDP300EC, GDP330EC, GDP360EC
F876 GDP80-120DC, GDP100DCS GDP190-280DC, GDP230DCS
F877 GDP130-160EC GDP360-360EC
G876 GDP80-120DC, GDP100DCS GDP190-280DC, GDP230DCS
G877 GDP130-160EC GDP360-360EC
General
This manual contains the description and repair procedures for the two stage mast and its components. The com-
ponents of the mast include the inner and outer mast, tilt and lift cylinders, carriage and forks.
Description And Operation

MAST SYSTEM TILTING
The function of the mast assembly is to lift a load ver- The mast pivots on pins, which are bolted to the outer
tically. It consists of an outer mast, inner mast and a mast. The pins rotate in bushings that are installed in
carriage. The outer mast is attached to the truck the mast mounts at the front of the frame. By extend-
frame. Inside the channels of the outer mast, the inner ing or retracting the tilt cylinders, the mast tilts forward
mast moves up and down, guided by rollers. Inside or backward. The maximum tilt angles are determined
the channels of the inner mast, the carriage moves up by the end stroke positions of the tilt cylinders. The
and down guided by rollers. The forks or an attach- length of the two tilt cylinders must be adjusted to pre-
ment are mounted on the carriage. vent the tilt cylinders from twisting the mast in the
maximum back tilted position.
The vertical movement of the inner mast and carriage
is provided by two lift cylinders and lift chains. For- The hydraulic pressure in the tilt cylinders is deter-
ward and backward tilting of the mast is provided by mined by the combined weight of the mast assembly
the tilt cylinders. Different carriage options are availa- and the load, and by the horizontal distance between
ble for side shifting, fork positioning or for attach- the mast pins and the combined point of gravity of
ments. mast and load.
The masts for GDP80-120DC and H300-360HD2 A valve is installed in the connection with the rod side
trucks are similar, and only differ in the dimensions of of the tilt cylinders to improve control of tilt cylinder
their components. movement. This valve can be a counterbalance valve
or a relief valve.
1
Description And Operation 4000 YRM 1647
A counterbalance valve is installed on E876 and E877 The lowering control valve is a pressure compensated
units produced before November 2012. The counter- valve. It allows an increasing flow with increasing
balance valve has no oil flow restriction when tilting pressure until a preset maximum flow is reached. The
backward. The counterbalance valve acts as a result is that similar lowering speeds are obtained for
35 MPa (5076 psi) relief valve as pressure builds up loaded and unloaded conditions. The primary function
at the rod side of the tilt cylinders. When tilting for- of the lowering control valve is to limit the lowering
ward, supply pressure at the piston side opens the speed in case of a malfunction of the supply/return
counterbalance valves and relieves pressure at the connection. The different lift height capacities are de-
rod side of the tilt cylinders. To prevent racking of the termined by the dimensions of the various mast as-
mast, the counterbalance valves must be adjusted to semblies. The lowest position of the forks is deter-
obtain equal pressures in the two cylinders when tilt- mined by the adjustment of the chain anchors.
ing forward.
A relief valve is installed on lift trucks manufactured

after November, 2012. When tilting forward, additional
oil pressure must be applied at the piston side, above
the pressure which is required for tilting. This addi-
tional oil pressure is required to open the
14 MPa (2031 psi) relief valves.
LIFTING
The lift cylinders are supported at the base of the

outer mast. When the cylinders extend, they push the
inner mast upwards. The chains are attached to the
outer mast and carriage, and they run over the chain
sheaves at top of inner mast. When inner mast moves
upwards, chains pull the carriage upwards to twice
the distance that the lift cylinders have extended. See
Figure 1.
Operation
The lift cylinders extend when hydraulic pressure ap-

plied is sufficient to lift the combined weight of the
load, forks, carriage and inner mast. Lowering is ach-
ieved by releasing hydraulic pressure, which is in- 1. LIFT CYLINDERS
2. OUTER MAST
duced by the weight resting on the rod of the lift cylin- 3. INNER MAST
ders. 4. CHAIN SHEAVE
5. LIFT CHAIN
Lifting speed and lowering speed are controlled by the 6. CARRIAGE
moved position of lift spool in the main control valve.
Figure 1. Operation of a Two-Stage Mast
Maximum lifting speed is determined by maximum
pump supply. Maximum lowering speed is determined
by the lowering control valve at the bottom of each lift
cylinder.
2
4000 YRM 1647 Description And Operation
Pilot Operated Check Valves The pilot operated check valve opens when pressure
at the cylinder side of valve exceeds the combined
The lift spool in the main control valve does not seal force of spring and oil pressure at the pilot side. Oil
completely in the neutral position. To obtain zero leak- pressure at the pilot side of the check valve reliefs to
age, a pilot operated check valve is mounted in the tank by opening the pilot operated selector valve. The
main control valve between lift spool and lift cylinder. pilot operated selector valve is opened by pilot pres-
See Figure 2. sure from the lift spool, when the lift spool has moved
into the lowering position.
When raising the mast, oil supply will pass through a
check valve in the pilot operated check valve. To Lowering the lift cylinders can be interrupted by re-
lower mast, the pilot operated check valve must be turning the lift spool into the neutral position, which in-
moved into the open position. The position of the pilot terrupts pilot supply to the pilot operated selector
operated check valve, is determined by oil pressure at valve, causing the selector valve to close. The closed
the cylinder side of the check valve, and by the com- selector valve allows lift cylinder pressure to build up
bined force of a spring and oil pressure at pilot side of at the spring side of the check valve, causing the pilot
check valve. Spring force will keep the check valve operated check valve to close as well. See Figure 2.
closed when equal pressures exist at the pilot side
and cylinder side of the check valve.
1. PILOT OPERATED CHECK VALVE 3. PILOT SIDE

2. EMERGENCY LOWERING VALVE (IN LH LIFT 4. PILOT OPERATED SELECTOR VALVE
SECTION ONLY) 5. CYLINDER SIDE
Figure 2. Pilot Operated Valves – Schematic
3
Gland Lubrication valve. This situation occurs for instance, when the
weight of carriage has been removed from lift cylin-
To provide lubrication to the seals in the gland, the ders. The emergency lowering valve provides the
rod side inside the lift cylinder is filled with hydraulic possibility to manually relieve lift cylinder pressure to
oil. When the cylinder extends to highest position, tank.
some of the oil moisturizes the gland seals.
The emergency lowering valve combines three func-
The area between shell and rod is closed off by a tions in one assembly. The anti-cavitation valve opens
1 MPa (145 psi) check valve, which is located at the when lift cylinder pressure is lower than tank pres-
lower cross member of outer mast. The function of the sure. The shock valve opens when (under extreme
1 MPa (145 psi) check valve is to retain air pressure conditions) lift cylinder pressure exceeds
at the rod side. 35 MPa (5076 psi). Turning the hand wheel clock
wise, opens the shock valve against spring force. See
When the cylinder extends, the increasing air pres- Figure 3.
sure between shell and rod pushes the oil through the
holes into the inside of the rod. When the cylinder re- Operation
tracts, the reducing air pressure at the shell side al-
lows oil to return from the rod inside to the highest The emergency lowering valve is located at the left
possible position on the rod outside. hand side of the main control valve. See Figure 3. Ini-
tial turning of the hand wheel CLOCKWISE will re-
Emergency Lowering Valve move play between spindle and shock valve. Contin-
ued turning clockwise opens the shock valve against
The lift cylinders will NOT lower if lift cylinder pressure spring force and allows oil from the lift cylinders to
is insufficient to overcome the combined force of the drain to tank. See Figure 4.
spring and the oil pressure at the pilot side of check
1. EMERGENCY LOWERING CONTROL VALVE
Figure 3. Emergency Lowering Control Valve - Location
4
A. TO TANK
B. FROM CYLINDER
1. SHOCK VALVE 1. OUTER PLATES
2. ANTI-CAVITATION VALVE 2. LINK PIN (RIVETED TO OUTER PLATES
3. SHOCK VALVE SPRING 3. INTERMEDIATE PLATES
4. ANTI-CAVITATION SPRING 4. INNER PLATES
5. SPINDLE 5. OUTER LINK
6. HAND WHEEL 6. INNER LINK
Figure 4. Emergency Lowering Valve Assembly Figure 5. Chain Components
The emergency lowering valve closes by turning the

Elongation Through Wear
hand wheel COUNTER CLOCKWISE. After the spin-
dle loses contact with the shock valve, continue to
When the chain articulates, the inner plates rotate
turn the hand wheel counter clockwise as far as it
over the link pin and cause wear. Wear reduces the
goes. This allows the Anti-Cavitation Valve to open
pin diameter and enlarges the hole in the plate, which
when necessary. Immediately after, turn the hand
results in chain elongation. When elongation has
wheel one turn back to prevent damage in case an
reached 3%, the entire chain must be replaced.
operator is not familiar with the correct direction of
hand wheel rotation.
Speed of Wear
Lift Chains
The speed of wear of link pin and inner plates de-
pends on the following factors:
The lift chains are leaf type chains. A leaf chain con-
sists of link pins and plates that are made of special • Load and impact load. The chain load de-
steel. Heat treatment and mechanical processing give pends on the weight lifted and the weight of the
the pins and plates their final strength, but they also carriage and forks. Impact loads occur, when
make these components more vulnerable to fatigue the truck drives over uneven surfaces. The
fractures, if pin and plate surfaces are damaged. forces generated by an impact load can be a
multiple of those of normal chain load.
The link pins are riveted into the outer plates. The • Number of link movements. The number of
press fit of the link pins in the outer plates is essential link movements directly relates to the number
for the integrity of the chain. of times the chain passes over the sheave
when the mast is raised or lowered. Chain
The inner plates have a tight sliding fit for an opti- elongation must therefore be measured at that
mized carrying area that also allows rotation over the chain section that runs over the sheave most
link pin. See Figure 5. often. The chain section close to the carriage
will have the lowest number of articulations and
The chains are connected to the carriage and outer is irrelevant for measuring chain elongation.
mast through chain anchors. The pin between chain
anchor and chain is secured with a snap ring.
5
• Lubrication. An oil film at the contact area be- trate again. Restoring the oil film is effected by the ca-
tween link pin and inner plates reduces wear pillary action of oil. This process is to be considered
and preserves the smooth surface of this con- separately from applying new oil to the chain.
tact area. The oil film is particularly important
for new chains, when the contact areas are be- Restoring The Oil Film
ing broken in. Therefore, it is essential that new
chains are lubricated with oil before they are The capillary action of oil allows restoring the oil film
put into service. between chain pin and inner plates, provided that suf-
See Figure 6. ficient free flowing oil is present between the plates,
and provided that chain tension is as low as possible
during a certain time.
The required time to maintain this low chain tension

varies with chain cleanliness and availability of free
flowing oil between the plates. This time can be as
short as 30 minutes or extend infinitely when condi-
tions are unfavorable.
Chain tension should not exceed the own weight of

the chain when restoring the oil film. This means that
chains must be slack.
Interruption of the oil film between pin and chain out-

side reduces the capillary action, but also allows entry
of humidity. Humidity activates the formation of corro-
sion products, making it even more difficult for oil to
A. CONTACT AREA reach the pin contact area. This means that new fresh
oil must be applied to the chain before the oil film on
Figure 6. Contact Area Between Link Pin and the outside is interrupted.
Inner Plates.
Maintenance
Plate Height Wear The purpose of applying new oil to chain is to replen-
ish free flowing oil and restore outside oil film. Adding
The chain plates also wear at the contact area be- new oil will extend the proper conditions for restoring
tween chain and chain sheave. When the chain the oil film at the pin area.
moves onto the sheave, the plates rotate slightly to
follow the radius of the sheave. In combination with The interval for applying new oil depends on load ap-
the high pressure between chain plates and sheave, plied, the number of chain articulations, and ambient
this movement causes wear, which affects the conditions like rain, temperature, presence of dust
strength of the plates. The maximum allowed wear is and dirt.
5% of the original link plate height.
In many cases the simple application of oil on the
Lubrication chains is sufficient to cover the period until the next
planned service interval. Main pre-condition is that
An oil film at the contact area between link pin and in- contamination has not progressed too far, which
ner plates reduces wear and preserves the smooth would prevent oil to penetrate.
surface of this contact area. See Figure 6.
Periodically the chains will have to be removed from
The oil film between pin and plates is pushed away the truck for cleaning, inspection and re-lubrication by
under load conditions and must be allowed to restore immersion in oil. Cleaning must allow thorough visual
daily by removing the load and allowing oil to pene- inspection and must be aimed at the removal of wear
particles and used oil at pin contact area.
6
Maintaining The Presence of Oil Requirements for Chain Lubricant
Insufficient lubrication permanently damages the The chain lubricant must be a mineral or synthetic en-
smooth contact area between chain pin and inner gine oil. Oil viscosity must match the ambient temper-
plates. Re-lubricating a damaged contact area after- ature, so that the oil remains viscous and can pene-
wards, will not restore the smooth finish of the contact trate contact area between link pin and intermediate
area. A damaged contact area causes accelerated link.
wear and increased friction. • Use SAE 20W to 30W oil in ambient tempera-
tures of −30 to 5°C (−22 to 41°F)
Increased friction may allow the inner plates to rotate
the pin in the outer plates. Once the pin has rotated in • Use SAE 40 oil in ambient temperatures of 5 to
outer plate, integrity of the chain structure is lost. Ro- 45°C (41 to 113°F)
tation of a pin in the outer plate is visible when the • Use SAE 50 oil in ambient temperatures above
beveled end of a pin no longer runs parallel to the 45°C (113°F)
length of chain. A chain must be replaced if a pin is at
an angle or if a pin has protruded. DO NOT use the following lubricant types:
• Lubrication products that contain solids such
Sufficient lubrication is particularly important for new as graphite or molybdenum disulfide. Solids
chains, which require a breaking in of the contact will not penetrate between the plates, and over
area. Proper breaking in also requires low load condi- time, they will form a barrier that prevents oil
tions during initial lifting and lowering. At least avoid penetration.
lifting high capacity loads initially.
• Grease or lubrication products that stiffen or
Corrosion Protection form a greasy film.
Stiffening products do not penetrate suffi-
ciently. Grease does not penetrate at all. Stiff-
Link pins and chain leaves are made of a steel type
ening products and grease form a barrier that
that is vulnerable to corrosion. Corrosion causes pits
prevents penetration of oil for re-lubrication.
which are the starting point for fatigue fractures. Cor-
Without proper lubrication, the service life of a
rosion preventing coatings, e.g. paint or grease, can-
lift chain is minimized.
not be applied to the chain as these would obstruct
the penetration of oil for re-lubrication. • Penetrating fluids or aerosol spray lubricants
containing penetrating fluids do not provide ad-
Therefore, the applied lubricating oil must also serve equate lubricity, adhesion or corrosion protec-
as a protection against corrosion. This outside oil film tion, and they do not form a film.
must always remain intact to make sure that humidity
does not reach the components of the chain, and cer- NOTE: If an aerosol spray lubricant is used, always
tainly not the contact area between pin and plate. check that it deposits an engine oil equivalent mini-
mum viscosity after the dispersing agent has evapora-
Circumstances like temperature, dust and rain will dic- ted.
tate the frequency of re-application of oil to the chain
to restore a protecting film. Re-apply oil before the oil
film is interrupted.
7
Load Rollers Bearing Blocks
Movement of the inner mast within the outer mast, The carriage and inner mast are equipped with bear-
and movement of the carriage in the inner mast are ing blocks. These absorb sideways forces, which can-
guided by load rollers to reduce friction. The load on not be absorbed by the load rollers. The bearing
the carriage causes forces on the load rollers in differ- blocks are shimmed close to mast channels. Re-shim-
ent directions. The lower load rollers are pushed ming is required when sideways movement causes
against the rear of the mast channels. The upper load shocks that affect load handling.
rollers are pushed against the front of the mast chan-
nels. See Figure 8. The bearing blocks on the carriage are located just
above the load rollers. On the mast the lower bearing
When the mast is tilted completely backward and the blocks are located above the lower rollers on the inner
carriage is raised, it is possible that the upper load mast. The upper bearing blocks are at the upper
rollers of the inner mast start traveling on the rear side channel end of the outer mast. See Figure 8.
of the outer mast channel, instead of the front side. To
reduce this backward movement of the inner mast in-
side the outer mast, mast support pads are installed
at the top of the outer mast. See Figure 7.
1. LOAD ROLLER
2. BEARING BLOCK
3. INNER MAST
Figure 8. Bearing Blocks and Load Rollers on

1. OUTER MAST Inner Mast
2. INNER MAST
3. LIFT CYLINDER
4. MAST SUPPORT PAD
Figure 7. Mast Support Pads
8
CARRIAGE Standard Carriage with Hydraulic Fork

Positioning
Three types of carriages are available for different
combinations of side-shifting and fork positioning. The pin-type forks are positioned by fork guides that
• The standard carriage can have manual or hy- are attached to fork positioning cylinders. By activat-
draulic fork positioning. ing the directional control valve the cylinders move
the guides and forks individually or simultaneously.
• The carriage with integral side shifting has a See Figure 10.
separate apron, which carries a pin type car-
riage. Sufficient grease must be present on fork pin and
• The dual function carriage is provided with fork lower carriage bar to reduce wear and friction during
carriers, which allow side shifting under load. fork positioning.
Standard Carriage with Manual Fork

Positioning
The pin-type forks are kept in position by two locking

pins. A spring ball keeps the pins in place. An attach-
ing cable keeps the pins from being lost. Each side of
the carriage has four holes to enable securing forks at
three different positions. The forks are repositioned
manually after releasing the locking pins from the car-
riage. See Figure 9.
1. CARRIAGE
2. FORK GUIDE
3. FORK
4. FORK POSITIONING CYLINDERS
Figure 10. Standard Carriage with Hydraulic Fork

Positioning
1. CABLE
2. LOCKING PIN
3. CARRIAGE
4. FORK
Figure 9. Standard Carriage with Manual Fork
Positioning
9
Dual Function Side Shift and Fork Positioning Integral Side Shift
(DFSSFP) Carriage
The carriage with integral side shift has a separate
Forks and fork guides for DFSSFP carriages are de- apron, which carries the forks. By activating the side
signed to side shift under loaded conditions. For this shift cylinder the entire apron is moved over the apron
purpose the fork has a bushing at the fork eye and pins. To reduce friction during side shifting the apron
each fork guide has a bearing block where it touches has bushings at the apron bracket and bearing blocks
the lower carriage bar. Both the bushing and bearing between apron and carriage. It is possible to have an
block are serviceable components. See Figure 11. apron with or without hydraulic fork positioning. Con-
struction and functionality of such aprons is similar to
the above described carriages. See Figure 12.
1. CARRIAGE
2. FORK GUIDE
3. FORK 1. CARRIAGE
4. FORK POSITIONING CYLINDERS 2. APRON PIN
3. APRON BRACKET
Figure 11. DFSSFP Carriage 4. FORK POSITIONING CYLINDER
5. SIDE SHIFT CYLINDER
6. FORK
Figure 12. Integral Side Shift
10
Carriage Valve Fixed P & T systems require three header hoses,

which have the following strap marking:
Different types of Valves can be installed depending • Green is connected with control valve port Aux
on the number and type of hydraulic functions on the A.
carriage. Oil supply is through header hoses, for ei-
• Yellow is connected with control valve port T3.
ther a Fixed Pressure and Tank (P & T) system or for
an Alternating Pressure & Tank system. An electrical • White-Yellow is connected with control valve
cable is routed over hose sheaves, parallel with port T Aux.
header hoses. For header hose connections see sec-
tion Step 4. NOTE: Nomenclature for the right and left fork posi-
tioner cylinder can be confusing. The right fork posi-
Alternating Pressure and Tank (P & T) tioner cylinder moves the right fork, however, the right
fork positioner is located at the left side of the car-
Alternating P & T is applied when a limited number of riage. See Figure 13.
functions allow the control valve on the truck to deter-
mine direction of oil flow. Examples are: one single
function, Simultaneous Fork Positioning only, and Flow Divider for Simultaneous Fork
Dual Function with Fork Positioning only. Positioning
For alternating P & T systems there are two header Simultaneous cylinder movement of the fork posi-
hoses, which are marked with two colored straps. tioner cylinders is controlled by a flow restrictor and
• Green-Yellow is connected with control valve two relief valves in the Flow Divider Manifold. The
port Aux A. flow restrictor provides an equal oil volume to the pis-
ton side of fork positioner cylinders. The relief valves
• Green-Green is connected with control valve maintain an equal pressure at rod side of the cylin-
port Aux B. ders when they extend. When the cylinders retract,
equal movement is controlled by flow restrictors only.
For alternating P & T systems, two different carriage
control valves are used: Differences in mechanical resistance of the two fork
• Flow divider for simultaneous Fork Positioning positioners and / or leakages may result in unequal
• Valve for Dual Function with Side Shift and cylinder extension positions. Correction of the cylinder
Fork Positioning (DFSSFP) end positions is obtained by a continued activation of
this function until both cylinders have reached their
Fixed Pressure and Tank (P & T) end positions. See Figure 13 and Figure 14.
Fixed P & T systems are applied when control valve

on the carriage determines the direction of oil flow to
different functions.
11
A. TO MAIN CONTROL VALVE PORT AUX B E. TO ROD SIDE RH FORK POSITIONER CYLIN-
B. TO MAIN CONTROL VALVE PORT AUX A DER
C. TO PISTON SIDE RH FORK POSITIONER CYL- F. TO ROD SIDE LH FORK POSITIONER CYLIN-
INDER DER
D. TO PISTON SIDE LH FORK POSITIONER CYL-
INDER
1. FLOW RESTRICTOR 2. RELIEF VALVE
Figure 13. Flow Divider Port Connections - Schematic
12
Valve for Dual Function with Side Shift and

Fork Positioning (DFSSFP)
Fork positioning is controlled by simultaneous activa-

tion of the Auxiliary spool in the main control valve
and activation of a fork positioner solenoid in the
valve for Dual Function with Side Shift and Fork Posi-
tioning (DFSSFP). Pressure will be applied to both
cylinders, but only the selected cylinder will be able to
move as its return oil escapes through the selected
solenoid.
The direction of cylinder movement is controlled by

selecting the A-side or B-side of the Auxiliary spool in
main control valve.
Side shifting is controlled by connecting the piston

sides of both cylinders and pressurization of one of
the cylinders at rod side. Oil extruding from the pres-
surized cylinder will move the piston of the second
cylinder. Activation of the Auxiliary A-spool activates
A. TO MAIN CONTROL VALVE PORT AUX B side shifting to the left until one of the cylinders has
B. TO MAIN CONTROL VALVE PORT AUX A reached its end-position. Activation of the B-spool ac-
C. TO PISTON SIDE RH FORK POSITIONER CYL- tivates side shifting to the right.
INDER
INDER Two relief valves limit supply pressure to
E. TO ROD SIDE RH FORK POSITIONER CYLIN- 20 MPa (2901 psi) for each of the supply lines. Each
DER solenoid valve has impact relief valves to protect the
F. TO ROD SIDE LH FORK POSITIONER CYLIN- system against pressure peaks. See Figure 15 and
DER
Figure 16.
1. FLOW RESTRICTOR
2. RELIEF VALVE
Figure 14. Valve for Simultaneous Fork
Positioning
13
A. TO MAIN CONTROL VALVE PORT AUX B E. TO PISTON SIDE RH FORK POSITIONER CYL-
B. TO MAIN CONTROL VALVE PORT AUX A INDER
C. TO ROD SIDE LH FORK POSITIONER CYLIN- F. TO ROD SIDE RH FORK POSITIONER CYLIN-
DER DER
INDER
1. SIDE SHIFT SOLENOID 3. RH FORK POSITIONER SOLENOID
2. LH FORK POSITIONER SOLENOID 4. RELIEF VALVE
Figure 15. Schematic for Dual Function Valve
14
Fixed Pressure and Tank System (Fixed P &

T)
Fixed P & T systems use a directional control valve

which can have up to four valve sections to operate
the different functions through solenoid valves. The
electric signal is provided by one wire harness for all
versions of this type of control valve. Unused harness
connectors are folded back against the wire harness
and taped in. See Table 3 for the identification of
functions, connectors and wire numbers.
Hydraulic operation of the directional valve is similar

to operation of the main control valve. The difference
in this directional valve is the absence of a line sens-
ing connection with the pump, the addition of a two
stage relief valve and addition of a pilot pressure sup-
ply valve.
The function of the two stage relief valve is to main-

tain supply pressure just above the required pressure
1. SIDE SHIFT SOLENOID (SS) - CONNECTOR as signaled by the internal LS line. Oil supply pres-
CPS 153 sure is regulated by relieving excess pressure through
2. LH FORK POSITIONER SOLENOID - CONNEC- port T3 in the main control valve. Maximum supply
TOR CPS 155
3. RELIEF VALVE pressure is regulated by the 19.5 MPa (2828 psi) re-
4. RH FORK POSITIONER SOLENOID - CONNEC- lief valve, which reliefs through Port T Aux in main
TOR CPS 154 valve.
5. PORT LEFT A - TO ROD SIDE RH FORK POSI-
TIONER The function of the pilot pressure supply valve is to
6. PORT RIGHT A - TO ROD SIDE LH FORK POSI-
TIONER maintain oil supply to a maximum pressure of
7. PORT LEFT B - TO PISTON SIDE RH FORK PO- 1.5 MPa (218 psi) for operation of auxiliary spools.
SITIONER See Figure 17 and Figure 18.
8. PORT RIGHT B - TO PISTON SIDE LH FORK
POSITIONER
9. PORT A1 - FROM CONTROL VALVE AUX A
10. PORT B1 - FROM CONTROL VALVE AUX B
Figure 16. Valve for Dual Function with Side Shift
and Fork Positioning (F876/F877 Shown)
15
1. HYDRAULIC FUNCTION 4. PILOT PRESSURE SUPPLY VALVE

2. INLET MODULE 5. SOLENOID
3. RELIEF VALVE 6. CYLINDER
Figure 17. Schematic for Fixed P& T Directional Control Valve
16
Forks
Two different fork constructions are used, depending

on type of carriage. The standard pin type fork is used
when the fork will not be moved under load. The ap-
plication is for different versions of fork positioning.
The dual function fork has a bushing to allow side
shifting under load. See Figure 19.
1. PORT B
2. PORT A
3. PORT T0 = CONNECTS WITH T AUX
4. PORT T = CONNECTS WITH T3
5. PORT P = CONNECTS WITH A AUX
6. INLET MODULE
7. 3RD FUNCTION
8. 4TH FUNCTION 1. STANDARD PIN TYPE FORK
9. 5TH FUNCTION 2. DUAL FUNCTION FORK
Figure 18. Directional Control Valve, Fixed P & T Figure 19. Fork Types
Systems
17
SAFETY PROCEDURES WHEN WORKING Follow these procedures:

NEAR MAST a. Put the mast in a vertical position.
The procedures below must be followed, when in- b. Raise the mast to align the bottom cross-mem-
specting or working near the mast. Additional precau- ber of the inner mast with a cross-member on
tions and procedures can be required when repairing the outer mast. See Figure 20.
or removing the mast. Follow the repair procedures in
this section. c. Use a 1/2 inch minimum safety chain with a
hook to fasten the crossmembers together so
the movable member cannot lower. Put the
WARNING hook on the back side of the mast. Make sure
Mast parts are heavy and can move. Distances be- the hook is completely engaged with a link in
tween parts are small. Serious injury or death can the chain. Make sure the safety chain does not
result if part of the body is hit by parts of the mast touch lift chains or chain sheaves, tubes, ho-
or the carriage. ses, fittings, or other parts on the mast.
• Never place any part of the body into or un- d. Lower the mast until there is tension in the
der the mast or carriage unless all parts are safety chain and the free-lift cylinder (two-
completely lowered or a safety chain is in- stage, full free-lift, and three-stage masts only)
stalled. Also make sure that the power is is completely retracted. If running, stop the en-
OFF and the key is removed. Place a DO gine. Apply the parking brake. Install a DO
NOT OPERATE tag in the operators com- NOT REMOVE tag on the safety chain(s).
partment.
• Be careful of the forks. When the mast is e. Install another safety chain (3/8 inch minimum)
raised, the forks can be at a height to cause between the top or bottom crossmember of the
an injury. carriage and a crossmember on the outer
weldment.
• DO NOT climb on the mast or lift truck at
any time. Use a ladder or personnel lift to 3. Apply the parking brake. After lowering or re-
work on the mast. straining the mast, shut off the power and remove
• DO NOT use blocks to support the mast the key. Place a DO NOT OPERATE sign in the
weldments nor to restrain their movement. operator's compartment.
• Mast repairs can require disassembly and
removal of parts and can require removal of
the mast or carriage. Follow the repair pro-
cedures in the correct Service Manual for
the mast.
WHEN WORKING NEAR THE MAST ALWAYS:
1. Lower the mast and carriage completely. Push

the lift/lower control lever forward and make sure
there is no movement in the mast. Make sure that
all parts of the mast that can move are fully low-
ered.
OR
2. If parts of the mast must be in raised position, in-

stall a safety chain to restrain the moving parts of
the mast. Connect moving parts to a part that
does not move. 1. OUTER 2. HOOK
Figure 20. Mast Safety Chains
18
BEFORE STARTING REPAIRS TO THE 7. Operate the lift and tilt levers completely forward
HYDRAULIC SYSTEM, ALWAYS: and backward to remove any trapped hydraulic
pressure.
1. Place the lift truck on a solid, level surface.
8. Apply the brake pedal until the brake lights do not
2. Apply the parking brake. longer come ON when the brake pedal is fully de-
pressed.
3. Tilt the mast completely forward.
9. Turn the key switch to the OFF position.
4. Lower the carriage and inner mast completely.
Make sure the lift cylinders are completely retrac- 10. Place blocks against both sides (front and back)
ted. of the tires to prevent movement of the lift truck.
5. Turn engine OFF.
6. Turn the key switch to the ON position.
Remove and Replace

FORKS 2. Position forks in front of hoist chains.
3. Place a pallet on a hydraulic jack or hand pallet

Remove
wagon. Place pallet under one of the forks. Lift
pallet at least 5 cm (2 in.) off ground.
WARNING
4. Place mast in a vertical position and lower mast
The mast assembly and its components are
until fork is stable on pallet.
heavy. To avoid causing damage or injuries, a lift-
ing device must be used during all service proce- 5. Attach fork guide to a lifting device. The fork guide
dures. weighs 12 kg (26.4 lb). Put tension on lifting de-
vice until it carries the weight of fork guide.
1. On carriages with manual fork positioning: re-
move retainer pins that secure forks.
Table 1. Fork Sizes And Weights
Model Type Fork Size Shortest Shortest Longest Longest

Fork Length Fork Weight Fork Length Fork Weight
GDP80-90DC Pin 65 x 200 mm 1220 mm 176 kg 2440 mm 266 kg
(GDP190-210DC) (2.6 x 7.8 in.) (48 in.) (388 lb) (96 in.) (586 lb)
GDP80-120DC Pin 75 x 200 mm 1220 mm 214 kg 2440 mm 336 kg
(GDP190-280DC) (3 x 7.8 in.) (48 in.) (472 lb) (96 in.) (741 lb)
Pin, PFT* 75 x 200 mm 1220 mm 187 kg 1825 mm 228 kg
(3 x 7.8 in.) (48 in.) (412 lb) (71.9 in.) (503 lb)
DFSSFP 70 x 200 mm 1220 mm 208 kg 2440 mm 422 kg
(2.8 x 7.8 in.) (48 in.) (459 lb) (96 in.) (930 lb)
GDP130-160EC Pin 90 x 200 mm 1370 mm 292 kg 2440 mm 422 kg
(GDP300-360EC) (3.5 x 7.8 in.) (54 in.) (644 lb) (96 in.) (930 lb)
DFSSFP 90 x 200 mm 1830 mm 374 kg 2440 mm 447 kg
(3.5 x 7.8 in.) (72 in.) (825 lb) (96 in.) (985 lb)
The approximate weight for alternative fork lengths can be calculated by extrapolation between shortest and
longest fork lengths. The indicated weights are for one fork. *PFT = Polished Fully Tapered
19
Remove and Replace 4000 YRM 1647
6. Remove capscrews and bracket that retain fork Move pin until there is sufficient space to
pin in carriage. See Figure 21. install fork.
b. For carriages with hydraulic fork position-
WARNING ing, move fork pin out of carriage until its
inner end is still inside the side plate of fork
Only remove the fork pin when the fork is properly
guide.
supported and when there is no tension on the
fork pin or damage and personal injury may oc- 5. Place each fork on a separate pallet.
cur.
6. Use a hydraulic jack or hand pallet wagon to posi-
NOTE: The fork pin weighs 55 kg (121.2 lb). For fork tion a fork in fork guide, while the back of fork
weights, see Table 1. touches carriage.
7. Use a hydraulic jack or hand pallet wagon to re- 7. Lift fork on pallet until fork pin aligns with the pin
lieve tension from fork pin and move fork pin until tube of fork.
its end has reached the fork.
a. For carriages with manual fork positioning, 8. Slide fork pin through fork pin tube to its final
attach a lifting device to fork pin with a mounting position in carriage.
sling and move fork pin out of fork.
9. Install bracket with four capscrews that retain fork
b. For carriages with hydraulic fork position- pin to carriage. Tighten bolts to 66 N•m (49 lbf ft).
ing, move fork pin just out of fork, but still
inside side plate of fork guide. 10. Repeat Step 1 through Step 9 to install remaining
fork.
8. Lower pallet with fork and move fork away from
truck. 11. Remove lifting devices.
9. Return fork pin to its assembled position and in-

stall retainer bracket. Remove lifting strap from
fork guide.
10. Repeat Step 4 through Step 9 to remove remain-

ing fork.
Install
1. Put mast in a vertical position and lower carriage
almost completely.
2. Position fork guides in front of hoist chains.
3. Attach a lifting strap and lifting device to fork

guide. The fork guide weighs 12 kg (27 lb). Put
tension on lifting strap until it carries weight of fork
guide.
NOTE: The fork pin weighs 55 kg (121.2 lb). The fork

weighs between 180 kg (396.8 lb) and
270 kg (595.2 lb).
4. Remove capscrews and bracket that retain fork 1. CAPSCREWS

2. WASHER
pin to carriage. See Figure 21. 3. BRACKET
a. For carriages with manual fork positioning, 4. FORK PIN
attach a lifting device to fork pin with a 5. RETAINER PIN
sling about one foot from inner end of the Figure 21. Fork - Remove
pin.
20
4000 YRM 1647 Remove and Replace
FORK GUIDE AND FORK PIN 4. Put a layer of grease on wear pad to attach it to
DFSSFP fork guide.
Remove
NOTE: The fork guide weighs 10 kg (22 lb) for fork
1. Position forks in front of hoist chains. positioners. The fork guide weighs 16 kg (35 lb) for
DFSSFP carriages.
2. Attach a lifting device at rod side of fork positioner
cylinder. 5. Use a lifting device to position one ear of fork
guide onto fork pin.
3. Remove securing pin and pin that connects the
cylinder rod to fork guide. See Figure 22. 6. Install fork. See section Forks, Install.
NOTE: The fork guide weighs 10 kg (22 lb) for fork 7. Install pin and securing pin that connect cylinder
positioners. The fork guide weighs 16 kg (35 lb) for rod of fork positioner cylinder to fork guide.
Dual Function Side Shift and Fork Positioning
8. Remove lifting device.
(DFSSFP) carriages.
4. Attach a lifting device to fork guide.
5. Remove fork. See section Forks, Remove.
6. Remove DFSSFP guide by sliding it off pin, lower-

ing hanger approximately two inches and then
move guide on ground. Take care to not loosen
wear pad at back of guide.
7. Remove standard guide for fork positioning by

sliding it off fork pin and putting it on ground.
NOTE: The fork pin weighs 55 kg (121.2 lb).
8. Attach a lifting device to fork pin at carriage out-

side.
9. Have fork pin supported at both ends before it is

removed entirely from carriage.
10. Remove fork pin and lower lifting device to put

fork pin on a pallet.
1. CAPSCREWS
Install 2. WASHERS
3. BRACKET
NOTE: The fork pin weighs 55 kg (121.2 lb). 4. FORK PIN
5. FORK GUIDE
1. Use a lifting device to lift fork pin. 6. CARRIAGE
7. FORK
2. Install one end of pin into carriage until it is in
front of hoist chains. Figure 22. Fork Guide And Pin
3. For Dual Function Side Shift and Fork Positioning

(DFSSFP) fork guides, use a new wear pad if pad
thickness is 20 mm (0.79 in.) or less. Minimum al-
lowable pad thickness is 15 mm (0.59 in.).
21
CARRIAGE 11. Attach a lifting device to carriage. Make sure that

lifting device is correctly positioned to pull car-
Remove riage in lifting direction of mast only.
NOTE: Carriage removal is necessary for inspection 12. Operate lifting device until lift chains of mast are
and replacement of load rollers and bearing blocks. slack.
All other serviceable carriage components can be re-
13. Disconnect lift chains from anchor chain. Remove
placed with carriage installed in mast.
split pin and washer from chain pin, support chain
1. Remove forks. See section Forks, Remove. anchor and remove chain pin.
2. Place lift truck on a solid, level surface. 14. Attach a strap through lower end of each chain.
3. Apply parking brake. 15. Attach straps around inner mast below two upper
mast roller stubs.
4. Tilt mast slightly backwards.
16. Connect a rope between strap at chain and inner
5. Turn engine OFF. mast. The ropes must have twice length of car-
riage height.
6. Turn key switch to ON position.
17. Disconnect electric mast cable from carriage
7. Operate lift and tilt levers completely forward and bracket and remove cable clamp. Place caps on
backward to remove any trapped hydraulic pres- all open electrical connectors.
sure.
18. Tag and disconnect header hoses at carriage
8. Apply brake pedal until brake lights do not longer bracket. Place plugs and caps at open fittings.
come ON when brake pedal is fully depressed.
19. Attach a 4 m (13 ft) long rope to header hoses
9. Turn key switch to OFF position. and tie rope to upper part of inner mast. This is to
prevent hoses from being pulled over the sheave,
10. Place blocks at front and back of all tires to pre-
and to give them sufficient slack when inner mast
vent movement of lift truck.
goes up.
Table 2. Carriage Weights
Model Type Weight

GDP80-90DC (GDP170-210DC) Standard 762 kg (1680 lb)
Standard with fork positioner 970 kg (2138 lb)
Side shift carriage 1266 kg (2791 lb)
Side shift with fork positioner 1358 kg (2987 lb)
GDP100-120DC, GDP100DCS Standard 912 kg (2994 lb)
(GDP230-280DC, GDP230DCS) Standard with fork positioner 1160 kg (2552 lb)
GDP130-160EC (GDP300-360EC) Standard 1382 kg (3047 lb)
Standard with fork positioner 1450 kg (3197 lb)
22
20. Start engine and operate lift cylinders to raise in- f. When dividing shims, make sure that left and
ner mast until mast channels are well above upright hand blocks extend a similar distance
per bearing blocks of carriage. from vertical carriage frame plates. Make sure
that this distance is the same at the same
21. Move lifting device with carriage away from mast plate.
and put carriage on blocks on the ground with
load rollers facing up. g. Install a new bearing block if more than 5
shims are required for correct shimming.
22. Lower mast completely and shut down engine.
h. When reinstalling a bearing block, tighten se-
Install curing bolt to 9 N•m (79.7 lbf in).
1. Place blocks at front and back of all tires to pre- i. After bearing block assembly is correctly shim-
vent movement of lift truck. med, tighten four bracket bolts to
44 N•m (32.5 lbf ft).
WARNING 4. Attach a lifting device to carriage.

Use caution when removing or installing the snap
rings used to fasten the load rollers to the stub 5. Lift carriage and move it in front of mast. Verify
shafts. The snap rings can come loose with force that upper and lower load rollers are parallel with
if not properly removed or installed. Wear eye and mast. Correct carriage position as necessary.
face protection when the snap rings are removed 6. Start engine and operate lift cylinders to raise in-
or installed. ner mast until mast channels are well above up-
2. Inspect rollers on carriage. If replacement is re- per bearing blocks. Tilt mast backward until mast
quired, remove snap ring and load roller from stub and carriage have same tilt position.
shaft. Install a new load roller and snap ring. See 7. Move carriage to position upper bearing blocks
section Load Rollers, Replace. into inner mast channels.
3. Verify correct shimming of bearing blocks. 8. Use the emergency lowering valve to lower mast
a. Measure distance between outer faces of bear- slowly. DO NOT damage bearing blocks when
ing blocks on carriage. they enter mast channel. See Figure 3.
b. Measure distance between inside of left and 9. Lower mast further until lower load rollers and
right hand channel of inner mast. Measure en- lower bearing blocks have entered. Lower mast
tire length of inner mast to establish shortest completely.
distance. Establish shortest distance with an 10. Reconnect lift chains to chain anchors.
accuracy of 0.5 mm (0.02 in.). See section
Mast Bearing Blocks, Install. 11. Lower lifting device, detach and remove from car-
riage.
c. Calculate actual play between inner mast and
bearing blocks by deducting distance between 12. Adjust chain length. See section Lift Chain, Lift
outer faces of bearing blocks (3a), from dis- Chains Adjustment.
tance between mast channels (3b).
13. Use rope to lower header hoses and electric ca-
d. Determine number of additional shims by de- ble. Remove rope.
ducting another 0.15 to 1.0 mm (0.006 to
0.039 in.) from actual play as calculated in (3c). 14. Remove caps and plugs and install header hoses
to fittings on carriage bracket.
e. Loosen four bolts that hold bracket to allow in-
serting required shims. 15. Maintain tension on electric mast cable while
tightening cable clamp. See Figure 23.
23
16. Attach electrical connector. See Figure 23.
17. Start engine and operate hydraulic functions on

carriage. Make sure that functions operate cor-
rectly. Check for leaks.
18. Remove blocks that have been placed at both

sides of tires.
1. CAPSCREW
2. WASHER
3. CARRIAGE
4. SHIM
5. BEARING BLOCK
Figure 24. Carriage Bearing Block
1. HEADER HOSES
2. ELECTRICAL CONNECTOR CLAMP
3. ELECTRIC MAST CABLE CONNECTOR
Figure 23. Carriage Bracket
Carriage Bearing Blocks
Remove
1. CAPSCREW
1. Remove carriage. See section Carriage, Remove. 2. WASHER
3. SHIM
2. If necessary, remove four capscrews and wash- 4. BEARING BRACKET
ers that retain bearing block bracket and shims to 5. BEARING BLOCK
carriage. See Figure 24. 6. SPACER
7. WASHER
3. Remove button head capscrew and nut that retain 8. BUTTON HEAD CAPSCREW
bearing block to bearing block bracket. See Fig-
Figure 25. Bearing Block Assembly
ure 25.
24
Install
NOTE: Install bearing blocks with curved side to-
wards load roller.
1. Measure distance between inside of left hand and

right hand channel of inner mast. Measure entire
length of inner mast to establish shortest dis-
tance. Establish shortest distance with an accu-
racy of 0.5 mm (0.02 in.). See Figure 26.
A. DISTANCE BETWEEN THE OUTER FACES OF

THE BEARING BLOCKS
Figure 27. Bearing Block Measurement

A. DISTANCE BETWEEN INNER MAST CHAN-
NELS
Figure 26. Inner Mast Channel Measurement Carriage Load Rollers
Replace
2. Temporarily place new bearing blocks for carriage
in bearing block brackets and measure distance Starting 2014, the masts have been provided with
between outer faces of bearing blocks. See Fig- greasable load rollers, which are retained by three
ure 27. bolts. Masts built before 2014 have non-greasable
load rollers, which are retained by a snap ring.
3. Determine number of required shims by deducting
distance as established in Step 2 from distance 1. Remove carriage. See section Carriage, Remove.
as established in Step 1.
2. Remove dirt to allow inspection of load rollers. Do
4. To obtain required clearance between mast and not clean.
carriage deduct another 0.5 to 1.0 mm (0.02 to
0.04 in.) from distance as established in Step 3. 3. Inspect rollers. The seals must be in good condi-
tion. Axial bearing play must be less than
NOTE: A maximum of five shims can be added be- 0.7 mm (0.028 in.). Grease must still be present in
hind bearing block in case bearing block is reused. If bearing. The roller must allow smooth rotation.
more than five shims are required, replace bearing
blocks.
5. Divide shims equally between left and right bear-

ing blocks. Shims are available in thicknesses of
0.5 mm (0.02 in.), 1.5 mm (0.06 in.), and
3.0 mm (0.12 in.).
25
Legend for Figure 28

WARNING
Use caution when removing or installing the snap 1. SNAP RING
2. LOAD ROLLER
rings used to fasten the load rollers to the stub 3. STUB SHAFT
shafts. The snap rings can come loose with force
if not properly removed or installed. Wear eye and
face protection when the snap rings are removed
or installed.
4. Remove the bolts or the snap ring from the stub

shaft and remove the load roller. See Figure 28
and Figure 29.
5. Install a new load roller, install the bolts or a new

snap ring.
6. Tighten the bolts to 40 N•m (29.5 lbf ft).
7. Install the carriage. See section Carriage, Install.
1. GREASE FITTING
2. BOLT
3. STUB SHAFT CAP
4. LOAD ROLLER
5. STUB SHAFT
6. CARRIAGE
Figure 29. Carriage Load Rollers, Greasable
Figure 28. Carriage Load Rollers, Non-Greaseable
26
Side Shift Cylinder 2. Remove outer snap ring on gland. See Figure 31.
3. Push gland into shell until retainer ring is ex-

Remove
posed.
1. Place lift truck on a solid level surface and apply
4. Remove retainer ring.
parking brake.
5. Pull rod assembly and gland from cylinder shell.
2. Retract side shift cylinder by side shifting to left
completely both cylinders by moving both forks to 6. Remove gland from rod.
center of truck.
7. Remove and discard the wiper, seal, back-up ring
3. Tilt mast completely backward and lower carriage and O-ring from gland.
and inner mast completely. Make sure lift cylin-
ders are completely retracted. 8. Do NOT remove piston form rod unless there is a
reason to replace seal between piston and rod.
4. Turn engine OFF.
9. Remove lock nut from rod and remove piston.
5. Turn key switch to the ON position.
10. Remove and discard seal and back-up ring from
6. Operate lift and tilt levers completely forward and piston.
backward to remove any trapped hydraulic pres-
sure. 11. Remove O-ring from rod at piston side.
7. Apply brake pedal until brake lights no longer

8. Turn key switch to the OFF position.
9. Place blocks against both sides (front and back)

of tires to prevent movement of lift truck.
10. Disconnect two hydraulic tubes from cylinder. See

Figure 30.
11. Install caps on the fittings of cylinder and hy-

draulic tubes.
12. Connect a lifting device to side shift cylinder. The

cylinder weighs 25 kg (55 lbf).
13. Remove nut from rod side of cylinder followed by

nut at cylinder side.
14. Pull carriage to right hand side of truck and re-

move side shift cylinder.
Disassemble 1. SIDE SHIFT CYLINDER

2. HYDRAULIC CONNECTIONS
1. Place side shift cylinder on a clean, horizontal 3. LOCKNUTS
surface.
Figure 30. Side Shift Cylinder Remove
27
1. LOCK NUT 8. EXTERNAL SNAP RING

2. PISTON 9. RETAINER RING
3. PISTON SEAL 10. WIPER
4. PISTON BACK-UP RING 11. SEAL
5. PISTON O-RING 12. BACK-UP RING
6. CYLINDER SHELL 13. GLAND O-RING
7. CYLINDER ROD 14. GLAND
Figure 31. Side Shift Cylinder Assembly
Clean And Inspect Assemble

1. Place O-rings and seals in hydraulic oil.
WARNING
Cleaning solvents can be flammable and toxic and 2. If removed, install a new O-ring at piston end of
can cause skin irritation. When using cleaning rod.
solvents, always follow the solvent manufac-
3. Install piston on rod and tighten lock nut. Tighten
turer’s recommended safety precautions.
nut to 260 N•m (192 lbf ft).
1. Clean all parts in a cleaning solvent and dry them
4. Install a new seal and back up ring onto piston.
with compressed air.
5. Install new seals and back up rings to gland.
2. Inspect parts of side shift cylinder for damage,
rust, or wear. 6. Apply hydraulic oil to inside of gland and slide it
onto rod.
3. Inspect rod surface closely to make sure it is free
of dents and scratches. 7. Apply hydraulic oil to outer diameter of piston and
gland and carefully slide piston and gland into
4. Make sure that internal stroke surface of cylinder
shell.
shell and grooves for seals do not show any
nicks, scratches, or other damage. 8. Push gland into shell until retainer ring can be in-
stalled.
5. Replace parts as needed.
28
9. Install a new retainer ring and pull rod with piston 8. Turn key switch to OFF position.
out of shell until gland stops on retainer ring and
snap ring groove is exposed. 9. Place blocks against both sides (front and back)
10. Install snap ring on retainer.
10. Disconnect two hydraulic tubes from cylinder. See
Install Figure 32.
1. Inspect and if necessary replace spherical bush- 11. Install caps on fittings of cylinder and hydraulic
ing at rod side of cylinder. tubes.
2. Slide washer and spherical bushing on cylinder 12. Connect a lifting device to positioner cylinder. The
rod. cylinder weighs 25 kg (55 lb).
3. Connect a lifting device to cylinder. The cylinder 13. Remove split pin and pin retaining rod side of cyl-
weighs 25 kg (55 lb). inder to fork guide.
4. Lift cylinder and insert rod at apron side of car- 14. Remove split pin and pin retaining rod side of cyl-
riage and install nut. DO NOT tighten nut. inder to carriage.
5. Move apron and insert stud at cylinder end into 15. Remove straps and hose from cylinder.
carriage. 16. Remove cylinder and repeat Step 12 through
6. Install washer and nut, rotate cylinder into correct Step 15 to remove other cylinder.
position and tighten nut to 300 N•m (221 lbf ft).
7. Tighten nut at rod side to 300 N•m (221 lbf ft).
8. Connect two hydraulic tubes to cylinder.
9. Start engine and operate hydraulic system. Make

sure that side shift cylinder works correctly.
Fork Positioner Cylinder
Remove
1. Place lift truck on a solid level surface and apply
parking brake.
2. Retract both cylinders by moving both forks to

center of truck.
3. Tilt mast completely backward and lower carriage

and inner mast completely. Make sure lift cylin-
ders are completely retracted.
4. Turn engine OFF. 1. FORK POSITIONER CYLINDER

2. SPLIT PIN
5. Turn key switch to ON position. 3. PIN
4. HYDRAULIC CONNECTIONS
6. Operate lift and tilt levers completely forward and 5. STRAPS
sure. Figure 32. Fork Positioner Cylinder

29
Disassemble 6. Remove gland from piston rod.
1. Place fork positioner cylinder on a clean, horizon- 7. Remove and discard piston seal from piston.
tal surface.
8. Remove and discard wiper, seal, back-up ring
2. Insert a pin face spanner into bores in gland and and O-ring from gland.
remove gland from cylinder shell. See Figure 33.
Clean and Inspect
CAUTION
Keep the piston rod aligned with the center line of WARNING
the cylinder shell during removal to avoid damage Cleaning solvents can be flammable and toxic and
to the cylinder parts. can cause skin irritation. When using cleaning
3. Carefully pull piston rod out of cylinder shell. turer’s recommended safety precautions.
4. Remove locking nut from piston retaining piston to 1. Clean all parts in a cleaning solvent and dry them
piston rod. with compressed air.
5. Remove piston from piston rod.
1. CYLINDER SHELL 7. PISTON SEAL

2. CYLINDER ROD 8. ROD SEAL
3. PISTON 9. WIPER
4. RETAINER 10. BACK-UP RING
5. NUT 11. O-RING
6. SPACER
Figure 33. Fork Positioner Cylinder Assembly
30
2. Inspect parts of cylinder for damage, rust, or 7. Start engine and operate hydraulic system. Make
wear. Inspect rod surface closely to make sure it sure that side shift and fork positioner cylinders
is free of dents and scratches. work correctly.
3. Make sure that internal stroke surface of cylinder Carriage Valves

shell and grooves for seals do not show any
nicks, scratches, or other damage.
Remove
4. Replace parts as needed.
NOTE: Most serviceable components can be re-
placed without removing the carriage valve. For re-
Assemble placement of a section in a fixed Pressure & Tank (P
1. Place O-rings and seals in hydraulic oil. & T) valve, it is necessary to remove and disassemble
the entire valve.
2. Install wiper, seal, back-up ring and O-ring to
gland. 1. Place lift truck on a solid, level surface.
3. Install seal to piston. 2. Apply parking brake.
4. Lubricate piston rod with hydraulic oil and install 3. Tilt mast completely forward.
gland onto piston rod. 4. Lower carriage and inner mast completely. Make
5. Install spacer onto piston rod. sure lift cylinders are completely retracted.
6. Install piston onto piston rod. 5. Turn engine OFF.
7. Install locking screw that retains piston to piston 6. Turn key switch to ON position.
rod. Tighten nut to 260 N•m (192 lbf ft). 7. Operate lift and tilt levers completely forward and
CAUTION sure.
Keep the piston rod aligned with the center line of 8. Apply brake pedal until brake lights no longer
the cylinder shell during installation to prevent come ON when brake pedal is fully depressed.
damage to the parts.
9. Turn key switch to OFF position.
8. Carefully slide piston rod and gland into cylinder
shell. 10. Place blocks against both sides (front and back)
9. Insert a pin face spanner into holes of gland and
install gland into cylinder shell. Tighten gland to 11. Tag and disconnect electrical connectors from
300 N•m (221.5 lbf ft). solenoids on the valve.
• For Fixed P & T Valves, see Figure 34.
Install
• For Simultaneous Fork Positioner Valves,
1. Connect a lifting device to cylinder. see Figure 37.
• For Dual Function Side Shift and Fork Po-
2. Position cylinder onto carriage. sitioning (DFSSFP) Valves, see Figure 38.
3. Install pin and split pin that retain rod side of cylin- 12. Tag and disconnect hydraulic supply and return
der to fork guide. hoses from hoses that connect to the directional
4. Install pin and split pin that retain cylinder side to control valve. Plug openings of hoses and valve.
carriage. 13. The valve for DFSSFP carriages is mounted on
5. Connect two hydraulic tubes to cylinder. bottom carriage bar. Remove three capscrews
under bottom carriage bar to remove valve.
6. Repeat Step 1 through Step 5 for other cylinder.
31
14. All other valves are mounted on a bracket at the 6. Connect the hydraulic hoses between the valve
top carriage bar. Remove the two nuts and wash- and the hydraulic functions.
ers at the upper side of the bracket. Lift the
bracket with the valve vertically over the mounting 7. Connect the electrical connectors to the solenoids
studs, to remove from the carriage. See Fig- on the valve. See Figure 35.
ure 35.
Valve for Fixed P & T Systems
Install
Remove and Disassemble
1. Mount the valve on the bracket with Torx screws.
1. Remove four torx screws that retain the P & T
2. Position the valve in the center on the top of the valve to bracket.
carriage.
2. Place the valve on a clean, horizontal surface.
3. Install the two cap screws and washers that retain
the valve to the carriage. See Figure 35. 3. Remove four capscrews that retain electrical end
cap to mid-section. See Figure 36.
4. Remove plugs and caps from the hydraulic lines
and ports. 4. Remove electrical end cap from mid-section.
5. Connect the supply and return hoses. 5. Repeat Step 2 and Step 3 to remove remaining
electrical end caps.
6. Remove four capscrews that retain the valve end

cap to mid-section.
7. Remove the valve end cap from mid-section.
1. PORT B
2. PORT A
3. PORT TO = CONNECTS WITH T AUX
4. PORT T = CONNECTS WITH T3
5. PORT P = CONNECTS WITH A AUX
6. INLET MODULE
7. 3RD FUNCTION 1. NUT
8. 4TH FUNCTION 2. WASHER
9. 5TH FUNCTION 3. BRACKET
4. P & T VALVE
Figure 34. Fixed P & T Valve Connections
Figure 35. Bracket for Fixed P & T Valve
32
8. Repeat Step 5 and Step 6 to remove remaining 11. Separate mid-sections and the end section.
valve end caps.
12. Remove the O-rings from the mid-sections and
9. Remove the three nuts from the tie-rods. the end section. See Figure 36.
10. Carefully remove the tie-rods from the valve. See

Figure 36.
A. PORT T0 = T AUX - ON MAIN CONTROL VALVE D. PORT A

B. PORT T = T3 - ON MAIN CONTROL VALVE E. PORT B
C. PORT P = A AUX - ON MAIN CONTROL VALVE
1. INLET MODULE 5. O-RING
2. END MODULE 6. VALVE HOUSING
3. TIE-ROD 7. SPOOL
4. SOLENOID 8. END CAP
Figure 36. Fixed P & T Valve Assembly
33
Clean and Inspect

WARNING
Be careful not to damage the threads of the tie-
WARNING rods during assembly of the mid-sections and
Cleaning solvents can be flammable and toxic and end-sections.
can cause skin irritation. If using cleaning sol-
vents, always follow the solvent manufacturer’s 3. Carefully place a mid-section over the three tie-
recommended safety precautions. Compressed rods against the end section.
air can move particles and cause injury to the
user or to other personnel. Make sure com- 4. Carefully place the remaining mid-sections over
pressed air path is away from all personnel. Wear the three tie-rods against the first installed mid-
eye protection. section.
1. Clean all parts of the fixed P & T valve with sol- 5. Carefully place the second end section against
vent and carefully dry the parts with compressed the mid-section.
air. 6. Install the three nuts onto the tie-rods and tighten
2. Check the valve end caps and bores for defects. to 26 to 30 N•m (230 to 266 lbf in).
If a valve end cap or bore is damaged, replace 7. Position a valve end cap to a mid-section.
the valve section that contains the damaged part
or parts. Make sure the bores and grooves for O- 8. Install the four cap screws that retain the valve
rings are smooth and do not contain dirt or have end cap to the mid-section and tighten to 7.5 to
defects. 8.5 N•m (66.6 to 75.4 lbf in).
3. Check the electrical end caps for damage and re- 9. Repeat Step 7 to install the remaining valve end
place the damaged electrical end caps. caps.
4. Check each tie-rods and nuts for thread damage 10. Position the electrical end cap against a mid-sec-
and replace the damaged tie rods and nuts. tion.
Assemble and Install 11. Install the four cap screws that retain the electrical
end cap to the mid-section and tighten to7.5 to
NOTE: Lubricate all parts using hydraulic oil before 8.5 N•m (66.6 to 75.4 lbf in).
assembly.
12. Repeat Step 10 and Step 11 to install the remain-
1. Install new O-rings to the valve housing and end ing electrical end caps.
caps. See Figure 34.
13. Install the fixed P & T valve to the bracket using
2. Place the three tie-rods in an end section. the four Torx screws.
Table 3. Spool Identification for Fixed P & T Systems
Function Hydraulic Connector Code Electrical Wire Numbers

Identification Identification
Side Shift 3rd function CPS 149 Aux 0 703-704
Left Fork Positioner 4th function CPS 150 Aux 1 705-706
Right Fork Positioner 5th function CPS 151 Aux 2 709-710
Auxiliary 6th function CPS 152 Aux 3 702-711
NOTE: For certain configurations, the functions Side shift and Fork Positioner can be replaced by an auxiliary
function. The auxiliary function will then receive the hydraulic and electrical identification of the function that is
being replaced.
34
Flow Divider for Simultaneous Fork 3. If necessary clean the valve with a petroleum
Positioning Valve based solvent.
4. Use new O-rings for installation.

Restrictor Valve and Relief Valve
Replacement 5. Install the valve and tighten to 35 to 40 N•m (310
to 354 lbf in).
1. Remove valve from housing.
6. Install the coil on the valve and tighten nut to 4 to
2. Instal new O-rings. 6 N•m (35 to 53 lbf in).
3. Install valve and tighten to 220 to 230 N•m (162 to 7. Replace the harness connector.
170 lbf ft). See Figure 37.
Dual Function Valve for Side Shifting and

Fork Positioning
Solenoid Valve Replacement

1. Remove connector from coil and remove the nut
that retains the coil to the valve.
2. Inspect the valve for wear and damage.
1. SIDE SHIFT SOLENOID (SS) - CONNECTOR

CPS 153
2. LH FORK POSITIONER SOLENOID - CONNEC-
TOR CPS 155
3. RELIEF VALVE
4. RH FORK POSITIONER SOLENOID - CONNEC-
TOR CPS 154
5. PORT LEFT A - TO ROD SIDE RH FORK POSI-
TIONER
6. PORT RIGHT A - TO ROD SIDE LH FORK POSI-
TIONER
7. PORT LEFT B - TO PISTON SIDE RH FORK PO-
SITIONER
A. TO MAIN CONTROL VALVE PORT AUX B 8. PORT RIGHT B - TO PISTON SIDE LH FORK
B. TO MAIN CONTROL VALVE PORT AUX A POSITIONER
C. TO PISTON SIDE RH FORK POSITIONER 9. PORT A1 - FROM CONTROL VALVE AUX A
D. TO PISTON SIDE LH FORK POSITIONER 10. PORT B1 - FROM CONTROL VALVE AUX B
E. TO ROD SIDE RH FORK POSITIONER
F. TO ROD SIDE LH FORK POSITIONER Figure 38. DFSSFP Valve
1. FLOW RESTRICTOR
2. RELIEF VALVE
Figure 37. Valve for Simultaneous Fork
Positioning
35
Relief Valve Replacement 12. Follow Step 6 through Step 11 to remove other lift
chain.
Remove
Install
1. Remove relief valve from housing.
1. Attach a hook to one of the lift chains at approxi-
Install mately 1 m (3 ft) from chain end. The hook must
be strong enough to hold weight of chain. Lead
1. Use new O-rings for installation. hook through links of chain and attach hook to a
lifting device.
2. Install valve and tighten to 220 to 230 N•m (162 to
170 lbf ft). 2. Lift chain until it is in front of chain sheave.
MAST 3. Attach a rope at the end of chain and lead rope

over sheave, through chain anchor hole in weld-
Lift Chains and Top Chain Anchor ment at top of mast. Pull rope to move chain end
above chain anchor hole.
Remove 4. Mount chain anchor through hole. See Figure 39.
1. Place truck on a solid, level surface. 5. Inspect chain pin for damage.
2. Place blocks of approximately 30 cm (1 ft) under 6. Install chain pin to connect lift chain to chain an-
carriage frame and lower mast until carriage rests chor. Install split pin and washer to secure chain
on blocks. pin.
3. Use the emergency lowering valve until the lift cyl- 7. Remove rope.
inders are retracted completely and the lift chains
are slack. 8. Lower lifting device and remove hook from chain.
4. Turn the engine OFF.
NOTE: Lift chains are heavy. See Table 6 for weights

of different chain lengths.
5. Attach a hook to one of the lift chains at top front

side of mast, approximately two feet below chain
sheave. The hook must be strong enough to hold
weight of chain. Lead hook through links of chain
and attach hook to a lifting device.
6. Remove split pin and washer from chain pins at

carriage chain anchors and then remove chain
pins.
7. Lift chain slightly until tension is removed from

chain pin that connects with chain anchor at top of
mast.
8. Remove split pin and washer from chain pin at top

chain anchor. See Figure 39.
1. SPLIT PIN
9. Support chain anchor and remove chain pin. 2. CHAIN PIN
3. CHAIN ANCHOR
10. Remove chain anchor.
Figure 39. Top Chain Anchor
11. Lower lifting device and put lift chain on a pallet.
36
9. Install chain pin at lower end of chain into carriage 8. Remove chain anchor from carriage.
chain anchor. Install washer and a new split pin.
Install
10. Follow Step 1 through Step 9 to install other lift
chain. 1. Position chain anchor in carriage. See Figure 40.
11. Start engine and raise inner mast to remove 2. Install large nut on chain anchor. If second chain
blocks under carriage. anchor was not removed, turn large nut until it has
reached a similar position compared with nut on
12. Lower mast and turn key switch to OFF position. second anchor chain.
13. Adjust chain length. See section Lift Chains, Lift 3. Install securing plate to carriage and lock nut to
Chains Adjustment. chain anchor.
14. Adjust tension of header hoses. See section 4. Inspect chain pin for damage.
Header Hose Tension Adjustment.
5. Connect lift chain to chain anchor by installing
Chain Anchor On Carriage chain pin. Install washer and a new split pin to se-
cure chain pin.
Remove
6. If second chain anchor was removed, repeat
1. Place truck on a solid, level surface. Step 1 through Step 3.
2. Put blocks of approximately 30 cm (1 ft) under 7. Install securing plate to carriage and lock nut to
carriage frame and lower mast until carriage rests chain anchor.
on blocks.
8. Start engine and raise inner mast to remove
3. Operate lever for lowering until lift cylinders are blocks under carriage.
retracted completely and lift chains are slack.
9. Lower mast completely and turn key switch to
4. Turn engine OFF. OFF position.
5. Remove split pin and washer from chain pins at 10. Adjust chain length. See section Lift Chains, Lift
carriage chain anchors, and remove chain pins. Chains Adjustment.
See Figure 40.
11. Bend fingers of securing plate around large nut.
NOTE: Before removing nut, note position of nut on
chain anchor. 12. Tighten bolt to secure plate to carriage.
6. Remove bolt that retains securing plate to car- 13. Tighten lock nut.
riage.
7. Bend securing plate and remove nuts and plate

from chain anchor.
37
6. Guide a strap through opening above chain

sheave and use strap to support sheave. The
chain sheave weighs approximately
4.4 kg (9.7 lb).
7. Remove capscrew and eye bolt from chain

sheave pin. See Figure 41.
8. Remove chain sheave from mast together with

spacers by lowering strap.
Install
1. Use a strap to position chain sheave in mast and
insert spacers. See Figure 42.
2. Insert pin into sheave.
3. Install eye bolt and secure it with capscrews.
4. Reinstall lift chains and adjust chain length. See

section Bob.
1. SPLIT PIN
2. CHAIN PIN
3. WASHER
4. CHAIN ANCHOR
5. LARGE NUT
6. SECURING PLATE
7. LOCK NUT
8. NUT
9. WASHER
10. CAPSCREW
Figure 40. Chain Anchor on Carriage
Chain Sheave
Remove
1. Place truck on a solid, level surface.
2. Put blocks of approximately 30 cm (1 ft) under in-

ner mast and lower mast until inner mast rests on
blocks.
3. Operate lever for lowering until lift cylinders are 1. INNER MAST
retracted completely and lift chains are slack. 2. SHEAVE PIN
3. EYE BOLT
4. Turn engine OFF. 4. WASHER
5. CAPSCREW
5. Remove lift chains. See section Lift Chains, Re-
Figure 41. Chain Sheave
move.
38
6. Disconnect hydraulic hoses from fittings at lower

mast bracket. Put caps on open fittings. See Fig-
ure 44.
7. Open hose clamps which retain hoses to the right

hand lift cylinder.
8. Disconnect hydraulic hoses from fittings on car-

riage bracket. Put plugs and caps on open fittings.
9. Remove hose cap.
10. Remove hoses.
1. SHEAVE PIN
2. SHEAVE
3. EYE BOLT
4. CAPSCREW
5. SPACERS
Figure 42. Sheave Spacer Location
Header Hoses
Remove
1. Place truck on solid, level surface.
2. Put blocks of approximately 30 cm (1 ft) under 1. HOSE SHEAVES

carriage frame and lower mast until carriage rests 2. SHEAVE CAP
on blocks. 3. SHEAVE BRACKET
4. UPPER MAST BRACKET
3. Operate lever for lowering until lift cylinders are 5. CAPSCREWS AND WASHERS
retracted completely and lift chains are slack. 6. HOSE CLAMPS
Figure 43. Hose Sheaves and Clamps

4. Turn engine OFF.
5. Release hose clamps on upper mast bracket, by

removing capscrews. See Figure 43.
39
Item Number Description Control Valve Carriage Valve Strap Color Code
Connection Connection
1 Supply T3 T Yellow
2 Supply A (AUX) P Green
3 Drain T (AUX) T0 White/Yellow
4 Breather Hose N/A N/A White/Green
5 Electric Cable N/A N/A CRP139/ CPS148
Item Number Description Control Valve Carriage Valve Strap Color Code
Connection Connection
1 Supply Aux B B1 Green/Green
2 Supply Aux A A1 Green/Yellow
3 N/A
4 Breather Hose N/A N/A White/Green
5 Electric Cable N/A N/A CRP139/ CPS148
A. MAST SIDE B. CARRIAGE SIDE

Figure 44. Header Hose Connections
40
Install 2. Connect electric mast cable with connector at car-

riage bracket.
1. Place hydraulic hoses over hose sheaves.
3. Install cable clamp at carriage bracket. Provide
2. Remove plugs and caps from hose fittings at car- some slack at carriage side for event that electric
riage side. mast cable has to be repositioned.
3. Connect hydraulic hoses to fittings on carriage 4. Insert connector at mast side in mast bracket and
bracket. install clamp ring. Reconnect mast cable with
frame harness. See Figure 44.
4. Connect hydraulic hoses to fittings on lower mast
hose bracket. 5. Install clamps that attach electric cable to mast.
5. Lift mast to remove blocks under carriage. Lower 6. Tension carriage side of cable and install clamp
carriage. on upper mast bracket.
6. Put tension on hoses and reinstall clamps at up-
per mast bracket. See Figure 43.
7. Install hose clamps which retain hoses to right

hand lift cylinder.
Electric Mast Cable
Remove
1. Turn engine OFF and disconnect battery cables.
2. Disconnect electric mast cable from frame har-

ness.
3. Open hose clamps retaining electric cable to right

hand lift cylinder.
4. Remove cable clamp at upper mast bracket. See

Figure 45.
5. Remove cable from sheave.
6. Disconnect cable from carriage bracket. See Fig- 1. SHEAVE BRACKET

ure 44. 2. INNER MAST
3. UPPER MAST BRACKET
7. Remove electric cable. 4. CAPSCREWS
Figure 45. Upper Mast Bracket and Sheave

Install Bracket
1. Put middle of electric cable over sheave.
41
Hose Sheave
Remove and Disassemble

1. Remove header hoses and electric mast cable.
See sections Header Hoses, Remove and Electric
Mast Cable, Remove.
2. Remove capscrew, spacer, washer, and hose

sheaves.
3. Slide hose sheaves and spacers from pin. See

Figure 46.
4. Inspect sealed bearings for wear. Replace entire

sheave if damaged.
Assemble and Install

1. Apply multipurpose grease to sheave pin.
2. Slide hose sheaves and spacers on pin. Both

spacers and hose sheaves can be installed either 1. CAPSCREW
way. 2. WASHER
3. SHEAVE PIN
3. Put additional grease at end of pin and install cap- 4. SHEAVE BRACKET
screw with washer. Tighten capscrew to 5. SHEAVES AND SPACERS
120 N•m (88 lbf ft). 6. SPACER
4. Install header hoses and electric mast cable. See Figure 46. Hose Sheaves
sections Header Hoses, Install and Electric Mast
Cable, Install.
42
Mast Assembly 9. Tag and disconnect hoses that lead to header

hose bracket.
Remove
10. Place plugs and caps on hoses and fittings on
1. Remove carriage. See section Carriage, Remove. header hose bracket. See Figure 44.
2. Lower inner mast and make sure lift cylinders are 11. Tag and disconnect hydraulic hose at base of
completely retracted. each lift cylinder.
3. Turn engine OFF. 12. Install plugs and caps on fittings at base of lift cyl-
inders and in hydraulic hoses.
4. Turn key switch to ON position.
NOTE: See Table 6 for the correct weights of the
5. Operate the lift and tilt levers completely forward mast. Make sure the lifting device has the proper ca-
and completely backward to remove any trapped pacity rating.
hydraulic pressure.
13. Strap lift chains and header hoses to lift cylinders
6. Apply and release the brake pedal until the brake to prevent them from moving while lowering mast.
lights do not longer come ON when the brake
pedal is fully depressed. 14. Connect a lifting device to lifting eyes on outer
mast. Position lifting device above lifting eyes. Put
7. Turn key switch to OFF position. tension on lifting device to have it carry weight of
mast. See Figure 47.
8. Disconnect mast lights harness from the mast
harness connector and disconnect the frame har-
ness from the mast harness connector at header
hoses bracket. See Figure 44.
Table 6. Mast Component Weights
Unit Lift Height Mast Assembly Inner Mast Weight Outer Mast Weight
Weight
GDP80-90DC 3686 mm (145.0 in.) 1510 kg (3328.9 lb) 509 kg (1122.1 lb) 677 kg (1492.5 lb)
(GDP190-210DC) 4586 mm (180.5 in.) 1670 kg (3681.7 lb) 578 kg (1274.3 lb) 728 kg (1604.9 lb)
5336 mm (210.0 in.) 1840 kg (4056.4 lb) 621 kg (1369.0 lb) 838 kg (1847.4 lb)
GDP100-120DC, 3686 mm (145.0 in.) 2060 kg (4541.5 lb) 762 kg (1679.9 lb) 817 kg (1801.2 lb)
GDP100DCS 4586 mm (180.5 in.) 2270 kg (5004.4 lb) 838 kg (1847.4 lb) 894 kg (1970.9 lb)
(GDP230-280DC,
GDP230DCS) 5336 mm (210.0 in.) 2510 kg (5533.5 lb) 902 kg (1988.5 lb) 1121 kg (2471.3 lb)
GDP130-160EC 3660 mm (144.0 in.) 2506 kg (5524.7 lb) 938 kg (2067.9 lb) 1217 kg (2682.9 lb)
(GDP300-360EC) 4560 mm (179.5 in.) 2771 kg (6108.9 lb) 1068 kg (2354.5 lb) 1309 kg (2885.8 lb)
43
g. Completely retract tilt cylinders and stop en-

gine.
16. Remove capscrews and washers from mast

mounting pins that connect mast to frame. See
Figure 49.
17. Use a soft hammer to remove the mast mounting

pins.
18. Lift mast away from truck.
19. Lower mast on blocks so mast mounts and tilt cyl-

inder mounts are facing up.
20. Place blocks under outer mast so that inner mast

can move.
1. LIFTING EYE
Figure 47. Lifting Eyes
WARNING
DO NOT push the cylinder pins out with your fin-
gers. DO NOT permit the tilt cylinders to drop and
cause damage or personal injury.
15. Disconnect tilt cylinders from mast as follows:
a. Put a wooden block between front fender and

tilt cylinder to support tilt cylinder.
b. At rod end, remove capscrew and eye bolt to

unlock pin that retains tilt cylinder to mast. See
Figure 48. 1. TILT CYLINDER
2. ROD END
c. Make sure wooden blocks are placed correctly 3. CAPSCREW
4. ANCHOR PIN
on front fender and support the tilt cylinder. 5. GREASE FITTING
6. EYE BOLT
d. Use a soft hammer to remove the tilt cylinder 7. WASHER
pin out of the tilt cylinder and the mast bracket. 8. LOCKING BOLTS
9. RELIEF VALVE (F876 ONLY)
e. Repeat Step a through Step d to disconnect 10. HYDRAULIC LINES
other tilt cylinder from mast. 11. PLUG
f. Start engine. Figure 48. Tilt Cylinder Connections
44
10. Remove isolator blocks at rear top side of outer

mast.
11. If installed, remove bearing block assemblies at

top of outer mast. See Figure 51.
12. Support lift cylinders to prevent them from falling

or moving.
13. Remove capscrews and washers that secure lift

cylinders to top of inner mast. See Figure 50.
14. Attach a lifting device to top cross member of in-

ner mast and pull inner mast half way out of outer
mast.
15. Attach any shim to cylinder if found installed at

top of cylinder. Apply right hand and left hand
markings to cylinders according their installation.
16. Remove securing bolt at bottom of lift cylinders.
17. Attach a lifting device to lift cylinders and remove

1. MAST them from outer mast.
2. CAPSCREWS
3. GREASE FITTING
4. SHIM WARNING
5. FRAME
6. BUSHING See Table 2 for the correct weight of the inner
7. MAST MOUNTING PIN mast. Make sure the lifting device has the proper
capacity rating.
Figure 49. Mast Mounted to Frame
18. Attach a lifting device to center of inner mast and
remove inner mast from outer mast.
Disassemble
1. Remove straps which temporarily retain chains
and header hoses.
2. Remove clamps that retain header hoses and

electric cable to right hand lift cylinder.
3. Remove hoses and cable. See section Header

Hoses, Remove.
4. Remove hoses connecting between lift cylinders

at top and bottom. Put caps on all open fittings.
5. Remove lowering control valve from lift cylinder

and put caps on open fittings.
6. Lead a hook through links of one of chains and at-

tach hook to a lifting device. 1. LIFT CYLINDERS
2. SMALL WASHERS
7. Remove split pin end pin to release chain from 3. WASHERS
upper chain anchor. 4. CAPSCREWS
Figure 50. Lift Cylinder Top

8. Remove chain and place it on a pallet.
9. Repeat Step 3 to Step 8 to remove other chain.
45
d. Determine number of additional shims by de-

ducting another 0.5 to 1.0 mm (0.02 to 0.04 in.)
from actual play as calculated in Step c.
e. Loosen four bolts for each bracket to allow in-

serting required shims.
f. When dividing shims, make sure that left and

right hand blocks extend a similar distance
from inner mast channel. Make sure that this
distance is same at same channel.
1. CAPSCREWS
2. WASHERS
3. BEARING BLOCK ASSEMBLY
Figure 51. Bearing Block Bracket
Assemble
1. TILT CYLINDER PIN
1. Inspect bushings for tilt cylinder pins in brackets 2. BUSHING
of outer mast. Replace if worn or damaged. 3. BUSHING SPLIT
4. GREASE CHANNEL
2. When reinstalling bushings, at mast side, make
Figure 52. Tilt Cylinder Bushings
sure that split in bushing is turned away by 45°
from centerline of tilt cylinder and is in virtually
highest position. See Figure 52.
3. Inspect load rollers on inner mast. If replacement

is required see instructions under Inner Mast
Load Rollers.
4. Verify correct shimming of bearing blocks.
a. Verify correct shimming of bearing blocks.
b. Measure distance between inside of left and

right hand channel of outer mast as shown in
Figure 53. Measure entire length of outer mast
to establish shortest distance. Establish short-
est distance with an accuracy of
0.5 mm (0.02 in.).
A. DISTANCE BETWEEN FACES OF OUTER
c. Calculate actual play between outer mast and MAST CHANNELS
bearing blocks by deducting distance between
outer faces of bearing blocks (Step a), from Figure 53. Outer Mast Channel Measurement
distance between mast channels (Step b).
46
g. Install a new bearing block if more than 5 15. Connect lift chain by installing chain pin and se-
shims are required for correct shimming. curing it with washer and a new split pin.
h. When reinstalling a bearing block, tighten se- 16. Install lowering control valve at bottom of lift cylin-
curing bolt to 9 N•m (80 lbf in). ders.
i. Do not yet install bearing block at top of outer 17. Install hoses connecting between lift cylinders at
mast. top and bottom.
j. After bearing block assembly is correctly shim- 18. Install header hoses and electric cable provision-
med, tighten four bracket bolts to ally over sheave and secure with straps.
44 N•m (32.5 lbf ft).
Install
WARNING NOTE: Inspect mast pins and bushings for wear prior
See Table 6 for the correct weight of the inner to install. Replace if required.
mast. Make sure the lifting device has the proper
capacity rating. 1. Install the bushings, grease the mast pin and in-
sert the pin with the grease fitting pointing to the
5. Attach a lifting device to center of inner mast and center of the truck.
install inner mast into outer mast until it is approxi-
mately 1 m (3 ft) from completely retracted posi- 2. Apply grease to the mast shims to stick them
tion. against the RH hanger. Position one shim at the
inside and two or three shims at the outside of the
6. Attach a lifting device to lift cylinders and install RH hanger. Turn the shims with their opening fac-
lower end into bottom cross member of outer ing up. Do NOT install shims at the LH hanger.
mast.
3. See for the correct weight of mast. Make sure lift-
7. Install securing washer with bolt at bottom of cyl- ing device has proper capacity rating.
inders. Tighten bolt to 35 N•m (26 lbf ft).
4. Connect a lifting device to lifting eyes on outer
8. Install bearing blocks at top of outer mast with mast. See Figure 48.
correct number of shims for a total play of 0.5 to
1.0 mm (0.02 to 0.04 in.). 5. Lift and position mast in front of lift truck.
9. Support lift cylinder to align its top end with 6. Lower mast hangers on mast pins.
mounting hole in inner mast.
7. Connect mast pins with hangers using 4 cap-
10. Install shims on lift cylinder if originally installed. If screws.
a different cylinder is installed, establish correct
shimming. See section Lift Cylinder, Install. Tighten capscrews to 435 N•m (321 lbf ft) for lift
truck models D876, E876, and F876
11. Retract inner mast to seat both lift cylinders.
Tighten capscrews to 522 N•m (385 lbf ft) for lift
12. Install securing washer with bolt at top of lift cylin- truck models D877, E877, and F877
der. Tighten bolt to 200 N•m (148 lbf ft). See Fig-
ure 50. 8. Connect tilt cylinders to mast as follows:
13. Install and shim isolator blocks to obtain a play of a. Turn engine ON.
0.5 to 1.5 mm (0.02 to 0.06 in.) between blocks b. Extend tilt cylinders until rods are almost in cor-
and inner mast channel. Tighten nut to rect position.
53 N•m (39 lbf ft).
c. Lift tilt cylinders to align holes in rods with
14. Position hoist chains at top of mast and lead one holes in mast.
chain end over sheave to top chain anchor.
d. Install tilt cylinder pins with lube fittings facing
outside of truck. See Figure 54.
47
15. Connect mast lights harness to the mast harness

connector and connect the frame harness to the
mast harness connector at header hoses bracket.
16. Adjust tension of header hoses and electric cable

after carriage has been installed.
WARNING
DO NOT try to locate hydraulic leaks by placing
hands on pressurized hydraulic components. Hy-
draulic oil can be injected into the body by pres-
sure.
17. Check for leaks.
18. Remove blocks on both sides (front and back) of

tires.
19. Lubricate the bushings for the mast pivot and the
tilt cylinder.
20. Reinstall carriage. See Carriage, Install.

1. TILT CYLINDER
2. ROD END
3. CAPSCREW
4. ANCHOR PIN
5. GREASE FITTING
6. EYE BOLT
7. WASHER
8. LOCKING BOLTS
9. RELIEF VALVE (F876 ONLY
10. HYDRAULIC LINES
11. PLUG
Figure 54. Tilt Cylinder Connections
e. Install eye bolts and capscrews to secure tilt

cylinder pins.
9. Disconnect lifting device from lifting eyes of outer

mast.
10. Adjust backward tilt position. See section Tilt Cyl-

inder Stroke and Backward Tilt Angle Adjustment.
11. Remove plugs at end of hydraulic header hoses.

1. SHEAVE PIN
12. Remove caps from fittings at lower mast bracket. 2. SHEAVE
3. EYE BOLT
13. Install the carriage. See Carriage, Install. 4. CAPSCREW
5. SPACERS
14. Connect header hoses to mast bracket. See Fig-
ure 55. Figure 55. Sheave Location
48
Inner Mast Load Rollers
Replace
Starting 2014, the masts have been provided with

greasable load rollers, which are retained by three
bolts. Masts built before 2014 have non-greasable
load rollers, which are retained by a snap ring.
1. Remove carriage. See Carriage, Remove.
2. Remove inner mast. See Mast Assembly, Re-

move.
3. Remove dirt to allow inspection of the load rollers.

Do not clean.
4. Inspect rollers. The seals must be in good condi-

tion. Axial play must be less than
0.7 mm (0.028 in.). The roller must allow smooth 1. SNAP RING
rotation. Verify slight binding caused by the pres- 2. LOAD ROLLER
ence of grease. 3. STUB SHAFT
Figure 56. Mast Load Rollers, Non-Greaseable

WARNING
Use caution when removing or installing the snap
rings used to fasten the load rollers to the stub
shafts. The snap rings can come loose with force
if not properly removed or installed. Wear eye and
face protection when the snap rings are removed
or installed.
5. Remove the bolts or the snap ring from the stub

shaft and remove the load roller. See Figure 56
and Figure 57 .
6. Install a new load roller with the bolts or a new

snap ring.
7. Tighten the bolts to 40 N•m (29.5 lbf ft).
8. Install inner mast. See Mast Assembly, Install.
9. Install carriage. See Carriage, Install.
1. GREASE FITTING
2. BOLT
3. STUB SHAFT CAP
4. LOAD ROLLER
5. STUB SHAFT
6. INNER MAST
Figure 57. Mast Load Rollers, Greaseable
49
Mast Bearing Blocks 2. Install new bearing blocks in bearing block brack-
ets. Tighten capscrew to 9 N•m (80 lbf in). DO
Remove NOT overtighten.
1. Remove carriage. See section Carriage, Remove. 3. Measure distance between outer faces of bearing
blocks.
2. Remove capscrew, washer and spacer which re-
tain bearing block. Remove bearing block. See 4. Determine number of required shims by deducting
Figure 58. result distance in Step 3 from result distance in
Step 1.
5. To obtain required clearance between mast and

carriage deduct another 0.5 to 1.0 mm (0.02 to
0.04 in.) from result distance in Step 4.
6. Divide shims equally between left and right bear-

ing blocks. Shims are available in thicknesses of
0.75 mm (0.03 in.).
7. Loosen four bolts which retain bearing blocks to

allow inserting correct number of shims.
8. Tighten bolts to 44 N•m (32 lbf ft).
1. BEARING BLOCK ASSEMBLY

2. SHIMS
3. CAPSCREWS
4. INNER MAST
Figure 58. Mast Bearing Block 1. CAPSCREWS
2. WASHERS
3. SHIMS
3. Remove button head capscrew retaining bearing 4. BEARING BRACKET
block and shims to bearing block bracket. See 5. BEARING BLOCK
Figure 59. 6. SPACER
7. WASHER
8. BUTTON HEAD CAPSCREW
Install
Figure 59. Bearing Block Assembly
1. Measure distance between inside of left and right
hand channel of outer mast as shown in Fig-
ure 60. Measure entire length of outer mast to es-
tablish shortest distance. Establish shortest dis-
tance with an accuracy of 0.5 mm (0.02 in.).
50
4. Remove fittings at top of lift cylinders.
5. Remove base hose between right hand and left

hand lift cylinder. See Figure 62.
6. Remove lowering control valve at bottom of lift

cylinders. Plug open ports.
7. Remove capscrews and washers that secure lift

cylinders to lower weldment of outer mast. See
Figure 63.
8. Attach a lifting device to top cross member of in-

ner mast.
9. Pull inner mast out of outer mast gently, until load

A. DISTANCE BETWEEN FACES OF OUTER
MAST CHANNELS rollers touch t upper mast bearing blocks.
Figure 60. Outer Mast Channel Measurement
WARNING
LIFT CYLINDERS The lift cylinder weight varies between 100 and
250 kg (221 and 551 lb), depending on the truck
Remove model. Make sure the lifting device has the proper
capacity rating.
1. Remove mast. See section Mast Assembly, Re-
move. 10. Attach a lifting device to one of the lift cylinders.
2. Unstrap chains and hoses from lift cylinders. 11. For high lift masts, remove top bracket at upper
weldment. See Figure 64.
3. Remove bleeder hoses from lift cylinders. See
Figure 61.
1. BALANCE LINE
2. LOWERING CONTROL VALVE
3. LIFT CYLINDERS
1. BLEEDER HOSES
Figure 61. Bleeder Hoses Figure 62. Lift Cylinder Base - Hoses
51
12. Remove capscrew and washers that retain cylin-

der at top of inner mast. See Figure 65.
13. Move cylinder towards bottom of inner mast, until

it comes out of bracket at top weldment. See Fig-
ure 64.
14. Move cylinder towards top of inner mast, slightly

twisting to inner side of mast, until lower end of
cylinder has come out of upper weldment.
15. Remove cylinder from mast.
16. Repeat Step 10 to Step 14 to remove other lift cyl-

inder.
1. CAPSCREWS
2. WASHERS
3. LIFT CYLINDERS
Figure 63. Lift Cylinder Base
52
NOTE: * INDICATES FOR HIGH MAST LIFT TRUCKS ONLY.
1. CAPSCREWS* 6. PLATE*
2. WASHERS* 7. OUTER MAST
3. LIFT CYLINDER* 8. INNER MAST
4. HOSE* 9. TOP BRACKET
5. BRACKET*
Figure 64. Lift Cylinder and Mast Arrangement
53
Legend for Figure 65
1. LIFT CYLINDERS
2. SMALL WASHERS
3. LARGE WASHERS
4. CAPSCREWS
Figure 65. Lift Cylinder Top
Disassemble
1. Place lift cylinder on clean, horizontal surface. Clean all parts in solvent and dry with compressed air.
Inspect parts of lift cylinders for damage, rust, or
2. Use a tool to remove gland from cylinder shell. wear. Carefully inspect rod surface to make sure it is
See Figure 66. free of dents and scratches. Make sure internal stroke
surface of cylinder shell and grooves for seals do not
show any nicks, scratches, or other damage. Repair
CAUTION
or replace parts as needed.
Keep the piston rod aligned in the center of the
cylinder shell during removal to avoid damage to
Assemble
the cylinder parts.
1. Apply packing lubricant and install wear band and
3. Keep rod aligned with cylinder and pull piston rod
piston seals onto piston and gland. See Fig-
out of cylinder shell.
ure 66.
4. Remove gland from piston rod. See Figure 66.
2. Apply packing lubricant and install gland onto pis-
NOTE: Mark each seal and ring location and position ton rod.
to aid in assembly.
5. Remove wear band and seal from piston rod. CAUTION

Keep the piston rod aligned in the center of the
6. Remove O-ring, backup ring, wear band, rod seal, cylinder shell during installation to prevent dam-
and wiper from gland. age to the parts.
Clean and Inspect 3. Carefully slide piston rod and gland into cylinder
shell.
WARNING 4. Use a tool to install gland into cylinder shell.

Cleaning solvents can be flammable and toxic and Tighten gland to 550 to 625 N•m (406 to
can cause skin irritation. When using cleaning 461 lbf ft).
5. Turn cylinder, until upper port faces up.
turer’s recommended safety procedures. Com-
pressed air can move particles so they cause in- 6. Lubricate gland seals by adding 7 liter (7.4 qt) of
jury to the user or to other personnel. Make sure hydraulic oil to breather port.
that the path of the compressed air is directed
away from all personnel. Wear protective goggles 7. Put a plug in upper port.
or a face shield to prevent injury to the eyes.
54
Install 6. Repeat Step 1 to Step 4 to install second cylinder.
1. Extend inner mast approximately 0.9 m (3 ft). 7. Lift top of cylinders to align them with upper
bracket in inner mast and retract inner mast until
2. Attach a lifting device to lift cylinder. Make sure both cylinders are inserted.
position of cylinder matches cylinder support at
bottom of mast. 8. Install washers and bolts that secure the top of lift
cylinder to inner mast.
3. Move top end of cylinder under top cross member
to upper cylinder bracket. 9. Tighten bolts at top and bottom of cylinder.
4. Lower bottom end of cylinder and position it into 10. Remove plugs from cylinders, use new O-rings
cylinder support at bottom of outer mast. and install fittings for bleeder hose and lowering
control valves.
5. Install large washer and capscrew provisionally at
bottom of cylinder. Make sure there is 11. Tighten lowering control valve to 150 to
2 mm (0.08 in.) play between large washer and 165 N•m (111 to 122 lbf ft).
mast support. If required, add small sized wash-
ers between cylinder cap and large washer. See 12. Install hose between left and right hand cylinder
Figure 67. base. See Figure 62.
1. CYLINDER SHELL 9. O-RING

2. LOCK RING 10. BACKUP RING
3. HYDRAULIC CONNECTION 11. NOT SERVICEABLE PART
4. ROD END 12. WEAR BAND
5. ROD SEAL 13. SEAL
6. WIPER 14. WEAR BAND
7. NOT SERVICEABLE PARTS 15. BOTTOM END
8. WEAR BANDS
Figure 66. Lift Cylinder Assembly
55
4. Lower carriage and inner mast completely. Make

sure lift cylinders are completely retracted.
5. Turn engine OFF.
6. Turn key switch to ON. position.
7. Operate lift and tilt levers completely forward and

sure.

come ON. when brake pedal is fully depressed.
9. Turn key switch to OFF. position.
10. Place blocks against both sides (front and back)

of the tires to prevent movement of lift truck.
11. Disconnect hydraulic hoses from tilt cylinder. Put

caps on hydraulic lines and ports.
12. For lift truck models F876 and F877 remove relief
1. LARGE WASHER valve from tilt cylinder to prevent damage during
2. CAPSCREW removal.
3. SMALL WASHERS
4. LOWERING CONTROL VALVE 13. For lift truck models E876 and E877 remove
5. LIFT CYLINDER END CAP counter balance valve from tilt cylinder to prevent
6. CYLINDER SUPPORT
damage during removal.
Figure 67. Lift Cylinder Bottom End
WARNING
13. Install bleeder hose between lift cylinders and The tilt cylinder weighs between 39 kg (86 lb) and
connect with bleeder hose leading to check valve 45 kg (99 lb), depending on truck and mast type.
at lower cross member. See Figure 63. Verify the lifting device has the rated capacity to
lift the tilt cylinder.
14. Install mast as described in section Mast Assem-
bly, Install. 14. Install a lifting device to tilt cylinder to be removed
and allow device to carry weight of cylinder.
15. Check shimming of hoist cylinders after mast has
been installed. See section Lift Cylinder Shim- 15. At rod end, remove capscrew and eye bolt to un-
ming. lock pin that retains tilt cylinder to mast. See Fig-
ure 68.
TILT CYLINDERS
WARNING
Remove Do not push the anchor pins out with your fingers.
Do not permit the tilt cylinders to drop and cause
NOTE: The following procedure is used to service
damage.
one tilt cylinder at a time. If both cylinders are to be
serviced at once, mast must be secured with a lifting 16. Use a soft hammer to remove pin from rod end of
device. tilt cylinder.
1. Place lift truck on a solid, level surface. 17. Lift tilt cylinder into an upright position.
2. Apply parking brake.
3. Tilt mast completely forward.
56
18. At frame side, remove capscrew and eye bolt to

unlock tilt cylinder pin that retains tilt cylinder to CAUTION
frame. Be careful not to damage the smooth surface of
the piston rod when removing the piston rod from
19. Use a puller tool to remove pin from cylinder end the cylinder shell in a horizontal position (parallel
of tilt cylinder. to the cylinder shell).
20. Lift tilt cylinder away from truck. 4. Pull piston rod assembly with gland out of cylinder
shell.
Disassemble
1. Put tilt cylinder in a vise with soft jaws, in a hori- CAUTION
zontal position. Be careful not to damage the grooves when re-
2. Disassemble and remove rod end by removing moving seals, wipers, and wear rings.
two locking bolts/nuts. See Figure 68. 5. DO NOT remove piston from rod unless there is a
3. Loosen gland from shell. reason to replace seal between piston and rod.
6. Disassemble and remove all seals, wipers, and

wear rings.
Clean and Inspect
WARNING
Cleaning solvents can be flammable and toxic and
can cause skin irritation. When using cleaning
turer’s recommended safety procedures. Com-
pressed air can move particles so they cause in-
jury to the user or to other personnel. Make sure
that the path of the compressed air is directed
away from all personnel. Wear protective goggles
or a face shield to prevent injury to the eyes.
Clean all parts in solvent and dry with compressed air.
Inspect parts of tilt cylinder for damage, rust, or wear.

Carefully inspect rod surface for dents and scratches.
Verify that internal stroke surface of cylinder shell and
1. TILT CYLINDER grooves for seals do not show any nicks, scratches,
2. ROD END or other damage. Replace parts as needed.
3. CAPSCREW
4. ANCHOR PIN
5. GREASE FITTING Assemble
6. EYE BOLT
7. WASHER NOTE: Verify that all parts are clean before assem-
8. LOCKING BOLTS bly. Always use new seals and O-rings. Lubricate all
9. RELIEF VALVES (F876 ONLY) parts with clean hydraulic oil.
10. HYDRAULIC LINES
11. LUBRICATION POINT 1. Assemble new seals, wipers, and wear rings ac-
Figure 68. Tilt Cylinder Connections cording to Figure 68.
57
2. If removed, install the piston on rod using a new Install

O-ring. Tighten nut to 950 to 980 N•m (700 to
725 lbf ft). NOTE: The locking bolts on rod end of tilt cylinder
should always be on bottom side with nuts towards
center of truck. See Figure 68.
CAUTION
Be careful not to damage the smooth surface of 1. Inspect bushings for tilt cylinder pins in brackets
the piston rod when installing the piston rod into for frame and outer mast. Replace bushings if
the cylinder shell in a horizontal position (parallel worn or damaged.
to the cylinder shell).
2. When reinstalling bushings, make sure that, at
NOTE: Keep the piston rod in the center of the cylin- mast side, split in bushing is turned away by 45°
der shell during installation to prevent damage to the from centerline of tilt cylinder and is in virtually
parts. highest position. See Figure 70.
3. Lubricate cylinder shell bore with clean hydraulic 3. Use a lifting device to move tilt cylinder to truck.
oil. Push piston rod assembly into cylinder shell.
4. Align cylinder and frame brackets.
4. Push gland onto cylinder shell. Lubricate threads
5. Grease tilt cylinder pin and insert it in frame
of cylinder shell with clean oil and tighten gland to
bracket.
550 to 600 N•m (400 to 450 lbf ft).
6. Install eye bolt and the capscrew. See Figure 69.
5. Assemble rod end onto rod.
7. Align cylinder and mast brackets.
1. ROD 7. CYLINDER SHELL

2. HOLE PLUG 8. PISTON
3. ROD WIPER 9. LOCK NUT
4. ROD SEAL 10. GUIDE RING
5. BACKUP RING 11. PISTON SEAL
6. O-RING 12. O-RING
Figure 69. Tilt Cylinder Assembly
58
8. Grease tilt cylinder pin and insert the pin in the 16. Apply grease to grease fittings, until grease es-
mast bracket using a soft hammer. capes from bushings.
9. Install eye bolt and capscrew. See Figure 69.
10. Tighten capscrews on both eye bolts to

165 N•m (122 lbf ft).
11. Install relief valve at rod side port of tilt cylinder.
For lift truck models (F876) and (F877), install relief

valve at rod side port of tilt cylinder.
For lift truck models (E876) and (E877), install

counterbalance valve at rod side port of tilt cylinder.
12. Connect hydraulic lines to tilt cylinder.
13. Operate tilt cylinders. Check for correct operation

and leakage. See section Lift and Tilt Cylinders
Leak Check.
1. TILT CYLINDER PIN
14. Adjust tilt cylinders as described in section Tilt 2. BUSHING
Cylinder Stroke and Backward Tilt Angle Adjust- 3. BUSHING SPLIT
4. GREASE CHANNEL
ment.
Figure 70. Tilt Cylinder Bushings
15. Tighten nuts on rod end to 66 N•m (49 lbf ft).
Checks and Adjustments

GENERAL CHECKS 1. Inspect welds on the mast and carriage for
cracks. Make sure that capscrews and nuts are
Mast Condition Check tight
2. Inspect forks. See section Forks, Fork Inspection

WARNING and Adjustment.
Lower the lift mechanism completely. Never allow
3. Inspect lift chains and their adjustment. See sec-
anyone under a raised carriage. Do not put any
tions Lift Chain Inspection and Step 2.
part of your body in or through the lift mechanism
unless all parts of the mast are completely low- 4. Inspect chain anchors and chain pins for cracks
ered and the engine is STOPPED. Before making and damage. Make sure lock nut on chain anchor
any repairs, use blocks and chains on the inner is locked.
and outer masts and carriage so that they cannot
move. Make sure the moving parts are attached to 5. Inspect rollers for wear or damage. Replace as
a part that does not move. necessary.
6. Check for leaks. Repair as necessary.

WARNING
Do not try to locate hydraulic leaks by putting 7. Check condition of hydraulic hoses and tubes.
hands on pressurized hydraulic components. Hy- Check hose covers for cuts, cracks or exposed
draulic oil can be injected into the body by pres- reinforcement. Replace as necessary.
sure.
59
Checks and Adjustments 4000 YRM 1647
Mast Operation Check Never repair damaged forks by heating or weld-

ing. Forks are made of special steel using special
1. Slowly raise and lower mast several times without procedures. Replace damaged forks.
a load. The mast components must raise and
lower smoothly in correct sequence. Repair as 1. Inspect forks for cracks and wear. Check that fork
necessary. tips are aligned within 3% of the length of forks.
Check that bottom of fork is not worn. See Fig-
2. Verify tensioning of header hoses and proper ure 71.
tracking over sheaves while lifting and lowering.
Re-adjust when required. 2. Replace any damaged or broken parts that are
used to keep forks locked in position.
3. Verify inner mast lowers completely. The inner
mast is lowered when lower side of inner and
outer mast channels are virtually flush with each
other.
4. Verify carriage lowers completely. The carriage is

completely lowered when forks almost touch the
ground when inner mast is completely lowered
and in a vertical position.
5. Check controls for attachment operate functions

of attachment as required. See Operating Man-
ual.
6. Verify mast and carriage do not move when lift

and tilt controls are in neutral position. Perform a
leak check (if any movement is observed), as de-
scribed in section Leak Checks.
Fork Tip Alignment
Counterbalance Valve Check (for E876 and Length of Forks 3% Dimension
E877 Only)
1220 mm (48 in.) 37 mm (1.5 in.)
1. Verify hydraulic oil is at operating temperature 1830 mm (72 in.) 55 mm (2.2 in.)
65°C (150°F).
2440 mm (96 in.) 73 mm (2.9 in.)
2. Tilt mast fully backwards.
1. TIP ALIGNMENT (MUST BE WITHIN 3% OF
3. Apply tilt forward lever 50% of its possible stroke. FORK LENGTH)
Both tilt cylinders should start moving out simulta- 2. CRACKS
3. FORK PIN DAMAGE
neously. 4. MUST BE 90% OF DIMENSION X
5. FORK WEAR
4. Adjust counterbalance valve if one tilt cylinder has
moved more than 3 mm (0.12 in.) before the other Figure 71. Check the Forks
tilt cylinder starts moving. See section Counter-
balance Valve Adjustment.
Fork Inspection and Adjustment
WARNING
Do not try to correct the alignment of the fork tips
by bending the forks or adding shims. Replace
damaged forks.
60
4000 YRM 1647 Checks and Adjustments
Lift Chain Inspection 6. Check for chain noise. Check if the chains pro-
duce a squeaking/squalling or grinding noise as
the mast is extended and lowered. Chain lubrica-
WARNING tion has been insufficient when such noise ap-
Never replace just the worn section of a chain. Re- pears. As a consequence the smooth surface be-
place the complete chain. Never replace just one tween pin and plate is probably damaged. In-
chain of a chain pair. Replace both chains. When crease frequency of lubrication.
replacing lift chains always discard the old chain
pins at the chain anchors and replace them with 7. Inspect for signs of rust or brown lubricant.
new ones. Brown lubricant indicates that corrosion has affec-
ted chain pins and / or plates. The smooth surface
Perform below inspections in the sequence listed. Re- between pin and plate is probably damaged.
lubricate chains after all inspections are successfully Rapid chain wear is to be expected. When there
passed. See section Lift Chain Lubrication Procedure. are signs of rust, there is an increased risk for stiff
links and displaced link pins. Remove all exterior
1. Inspect for adequate chain lubrication. Check rust and dirt buildup with a brush and an oil based
that the oil film is intact on the outside of the chain solvent. Increase frequency of lubrication.
and that oil at the links is still free flowing. When
the oil film is found inadequate, there is an in- 8. Inspect for stiff or tight chain links. Stiff articu-
creased risk for a chain failure caused by corro- lation of a chain link indicates a bent pin and/or a
sion and/or friction. Increase the frequency of lu- serious propagation of corrosion between pin and
brication. plate. A bent pin indicates an overload situation.
Replace both chains if any chain link suffers stiff
2. Inspect chain cleanliness. Clean chains when articulation.
dirt impedes penetration of lubricating oil into the
chain, or when dirt obstructs inspection. Only par- 9. Inspect for turned or protruding link pins.
affin derivatives such as diesel fuel or petroleum Check if beveled ends of link pins run parallel to
may be used as a cleaning agent. Use a brush to length of chain. If bevels of a link pin end are at
remove dirt and sand. an angle to the length of the chain, the link pin
has turned. A turned link pin indicates excessive
3. Measure chain elongation. Load the chain with friction due to insufficient lubrication or an over-
the weight of an empty carriage and measure dis- load condition. If a link is turned or protrudes, the
tance over at least 6 pitches, from pin center line integrity of chain is lost. Replace both chains if
to pin center line. Measure at several locations on any link pin is turned or protrudes. Increase fre-
the part of the chain that moves over the sheave. quency of lubrication.
Replace the chain if elongation is 3% or more. For
two inch pitch chain a 3% elongation has been 10. Inspect for broken link pins. Check that all
reached when pin distance over 6 links is outer plates run parallel to each other. A link pin is
314 mm (12.36 in.) or more. probably broken if outer plates are at an angle to
each other. A broken link pin indicates an over-
4. Measure remaining plate height. A reduced load situation. Replace both chains if any link pin
plate height reduces strength of the chain. Meas- is found broken.
ure the height of the plate. Replace both chains if
the height of any plate is 45.85 mm (1.80 in.) or 11. Inspect for broken or missing chain link
less. plates. Corrosion or an overload condition can in-
itiate fatigue fractures in plates. Replace both
5. Check alignment between sheave and chain. chains if any plate is found broken or missing.
Investigate if sheave and chain align properly. If
they do not align, one or both bearings in the 12. Inspect for damaged plates or pins. Impacts by
sheave, or the pin, or the sheave itself may be other objects may damage or deform plates or
damaged. Disassemble sheave, check each part pins. Deformation increases risk for fatigue frac-
for wear and replace if necessary. See section tures. Replace both chains if any deformation ex-
Step 3. ceeds 5% of the pin diameter or plate thickness.
61
Lift Chain Lubricant Requirements • Dry the chains. Make sure that any trapped
water or condensation, especially at the pin
Chain lubricant must be a mineral or synthetic engine area, is removed.
oil. Oil viscosity must match ambient temperature, so • Lubricate with a mineral or synthetic based en-
that oil remains viscous and can penetrate to contact gine oil. See section Lift Chain Lubricant Re-
area between link pin and intermediate link. quirements.
• Use SAE 20W to 30W oil in ambient tempera- • Make sure applied layer of oil protects the en-
tures of −30 to 5°C (−22 to 41°F). tire chain surface against corrosion.
• Use SAE 40 oil in ambient temperatures of 5 to • Allow sufficient time for oil to penetrate and fa-
45°C (41 to 113°F). cilitate oil penetration by articulating the chain
• Use SAE 50 oil in ambient temperatures above several times with the lowest possible load af-
45°C (113°F). ter oil has been applied.
The most practical oil to use is SAE 15W-40 multi Complete relaxation of chains between shifts signifi-
grade engine oil. cantly contributes to the re-lubrication of chain pins,
provided that the oil film on outside of chain is intact.
NOTE: If an aerosol spray lubricant is used, always
check that it deposits an engine oil equivalent, with Leak Checks
minimum viscosity as listed under Viscosity, after the
dispersing agent has evaporated. Mast Vertical Creep
DO NOT use the following lubricant types: 1. Place a capacity load on forks and raise and
lower load several times until hydraulic oil has
• Lubrication products that contain solids such
reached 65°C (150°F).
as graphite or molybdenum disulfide. Solids
will not penetrate between plates, and over 2. Raise forks approximately 1 m (3.3 ft) above
time, they will form a barrier that prevents oil ground, put lift controls in neutral position and
penetration. measure vertical creep during 10 minutes.
• Grease or lubrication products that stiffen or
form a greasy film. Stiffening products do not 3. Mast Vertical Creep must be limited to
penetrate sufficiently. Grease does not pene- 100 mm (3.94 in.) in 10 minutes for trucks up to
trate at all. Stiffening products and grease form 10 tons lifting capacity.
a barrier that prevents penetration of oil for re-
4. Mast Vertical Creep must be limited to
lubrication. Without proper lubrication, the serv-
200 mm (7.87 in.) in 10 minutes for trucks above
ice life of a lift chain is minimized.
10 tons lifting capacity.
• Penetrating fluids or aerosol spray lubricants
containing penetrating fluids do not provide ad- 5. If mast vertical creep exceeds maximum allowed
equate lubricity, adhesion or corrosion protec- value, determine if an internal leak is present at
tion, and they do not form a film. lift cylinder or at control valve.
6. Check lift cylinders for internal leaks.

Lift Chain Lubrication Procedure
7. Remove load from forks. Install a gate valve in
To achieve proper lubrication the following require- each of separate supply lines between lift cylinder
ments must be met. and control valve. Place again a capacity load on
• Remove the load from chain completely. Put a forks, raise forks approximately 1 m (3.3 ft) above
support under carriage and slacken chains. ground and close both gate valves. If creep speed
is similar to the measurement in Step 2, lift cylin-
• Clean the chain. Make sure that any debris,
ders need to be resealed.
grease or thick oil between chain outside and
link pin is removed.
62
8. Check functionality of Emergency Lowering The creep and drift rates reduce with a factor of about
Valve. Replace Emergency Lowering Valve to 1.5 for every 10°C (18°F) that actual oil temperature
verify if its replacement solves the problem. If in cylinder is lower. Make sure to have reached re-
creep speed is still too high, replace relevant con- quired oil temperature of 65°C (150°F) in cylinders for
trol valve section. Individual control valve section accurate test results.
components are not separately available.
ADJUSTMENTS
Mast Tilt Drift
Lift Cylinder Shimming
1. Place a capacity load on forks and tilt mast sev-
eral times forward and backward until hydraulic oil NOTE: Lift cylinders must be shimmed to make sure
has reached 65°C (150°F). that they equally support the inner mast in the com-
pletely lowered position. The purpose is to prevent
2. Attach an inclinometer to mast, put mast in a ver-
twisting the inner mast when driving with a load in the
tical position, and raise load at 2.5 m (8.2 ft)
completely lowered position.
height. Put controls in a neutral position and
measure mast tilt drift. Mast tilt drift must remain 1. Put mast in a vertical position and lower carriage
within 5 degrees during a 10 minute period. If completely. Make sure forks do not touch ground.
maximum forward tilt angle is less than 5 de-
grees, measured time period must be proportion- 2. Open emergency lowering valve. See Figure 72.
ally reduced.
3. Use a personnel lift and measure clearance be-
3. If mast tilt drift exceeds maximum allowed value, tween upper cylinder support and cylinder rod.
determine if an internal leak is caused by tilt cylin- Use a pry bar to make sure that cylinder rods can-
der or by control valve. not lower any further.
4. Check tilt cylinders for internal leaks. 4. Shimming is required when clearance exceeds
1 mm (0.04 in.). See Figure 73.
5. Remove load from forks. Install a gate valve be-
tween rod side of tilt cylinders and divider block. 5. Remove securing bolt and washers from cylinder,
Place again a capacity load on forks, raise forks which requires shimming.
approximately 1 m (3.3 ft) above ground and
close both gate valves. If creep speed is similar to 6. Use a lifting device to lift inner mast just enough
measurement in Step 2, tilt cylinders need to be to install shim on cylinder rod.
resealed.
7. Lower inner mast and install washers and secur-
6. Check control valve for internal leaks. ing bolt. Tighten bolt.
7. Check functionality of 28 MPa (4061 psi) pressure 8. Close emergency lowering valve.
relief valve in tilt section of control valve. Replace
relief valve to verify if its replacement solves prob-
lem. If creep speed is still too high, replace tilt
valve section.
63
A. EMERGENCY LOWERING VALVE
Figure 72. Emergency Lowering Valve Location
64
Lift Chain and Fork Height Adjustment 1. Put mast in a vertical position and lower carriage
completely.
CAUTION 2. Side shift the carriage until it is at the center line

The carriage can be set higher and lower on the of the mast.
lift chain anchor, however the carriage load rollers
3. Make sure that both forks are in an equally exten-
must remain within the inner mast channel both in
ded position.
the lowest and in the highest carriage positions to
avoid damage to the lift truck. 4. Measure the distance between the carriage bar
and the inner mast at two locations. The two loca-
NOTE: The purpose of lift chain adjustment is to
tions must be at 50 cm (2 ft) from each other. See
align the carriage in the inner mast and to position the
Figure 74, measuring point (A) and (B).
forks at the required height when the carriage is com-
pletely lowered. Carriage alignment is required when 5. Align the carriage if the two distances vary more
chains, chain anchors or the carriage is replaced. than 0.5 mm (0.025 in.).
Carriage alignment is also required when the carriage
does not lift and lower smoothly. A symptom is that 6. Make sure that both forks have at least
one of the chains has a lower tension and shows big- 1 cm (0.40 in.) clearance with the ground.
ger deflection compared with the other chain. Incor-
rect carriage alignment causes premature wear of the 7. If adjustment is required, loosen the chain anchor
bearing blocks. Alignment of the carriage is obtained lock nut and bend the fingers of the securing plate
by adjusting the two chain anchors individually. to release the large nut. See Figure 75.
8. Tighten the large nut of the chain anchor that is in

the lowest position to align the vertical carriage
bar with the inner mast channel.
9. Turn both large nuts with the same angle until the
required ground clearance has been obtained.
10. After adjustments are complete, bend the fingers

of the securing plates around the large nut and
tighten the lock nut.
A. SHIMMING GAP
1. CAPSCREW
2. SMALL WASHER
3. LARGE WASHER
4. OUTER MAST
5. INNER MAST
Figure 73. Lift Cylinder Shimming
65
A. MEASURING POINT A 1. SPLIT PIN

B. MEASURING POINT B 2. CHAIN PIN
3. WASHER
1. CARRIAGE 4. CHAIN ANCHOR
2. INNER MAST 5. LARGE NUT
3. OUTER MAST 6. SECURING PLATE
7. LOCK NUT
Figure 74. Carriage Alignment 8. SMALL NUT
9. WASHER
10. CAPSCREW
Figure 75. Chain Anchor On Carriage
66
Header Hose Tension Adjustment 4. Tighten cable clamp at carriage bracket.
1. Make sure that lift chains are tensioned and cor- Counterbalance Valve Adjustment
rectly adjusted.
1. Establish which tilt cylinder moves out first. See
2. Release hose clamp on upper mast bracket by section Counterbalance Valve Check (for E876
loosening capscrew. and E877 Only).
3. Verify that header hoses are in good condition. 2. Adjust the counterbalance valve which is at the
Un-tensioned hoses are to be of equal length. Re- opposite side of the valve connection for cylinder
place any defective hose. moving out first. See Figure 76.
4. Pull and tension hoses which are clamped on 3. Adjust the valve by loosening the adjustment nut
same bracket. The required elongation is between one full turn and subsequently rotate the setscrew
1% and 2%. ¼ turn counter clockwise.
5. Tighten capscrew to clamp hoses. See section 4. Retighten adjustment nut by using a 17 mm
Step 3. wrench.
Electric Mast Cable Tension Adjustment 5. Check again simultaneous cylinder movement.
See section Counterbalance Valve Check (for
1. Make sure that lift chains are tensioned and cor- E876 and E877 Only).
rectly adjusted.
6. Repeat adjustment procedure until both tilt cylin-
2. Loosen cable clamp at carriage bracket. ders start moving simultaneously when tilting for-
ward.
3. Pull and hold cable at same tension as header
hoses.
1. COUNTERBALANCE VALVE 4. LOCK NUT

2. VALVE TO ADJUST LH CYLINDER 5. SET SCREW
3. VALVE TO ADJUST RH CYLINDER
Figure 76. Counterbalance Valve Adjustment
67
Tilt Cylinder Backward Tilt Angle Adjustment 6. When adjustments are complete, turn rods until
wrench flats are at upper and lower side. Having
1. Slowly tilt mast backward until one rod is against wrench flats at sides of rods increases stress
its stop. Adjust opposite cylinder if it stops more level.
than 1.0 mm (0.04 in.) later.
7. Tighten nuts on rod end to 66 N•m (49 lbf ft).
2. To adjust tilt cylinder, loosen nuts on rod end and
turn cylinder rod out of rod end until both rods Mast Support Pad Adjustment
stop at same time.
1. Tilt mast slightly forward and measure clearance
3. Repeat procedure to make sure cylinder rods stop between wear plate and inner mast. Clearance
at the same time within 1.0 mm (0.04 in.). should be between 0.5 and 1.5 mm (0.020 and
0.059 in.).
4. Check tilt angles are correct as specified on
nameplate of lift truck. A limited tilt angle correc- 2. For re-shimming, remove capscrews and install
tion can be made by turning both cylinder rods the shims as necessary between wear plate and
same amount. outer mast.
5. Verify thread of cylinder rod extends approxi- 3. Tighten capscrews to 60 N•m (44.3 lbf ft). See
mately 48 mm (1.89 in.). See Figure 77. Turn both Figure 78.
rods into the rod end if one of the threads extends
more than 50 mm (1.97 in.).
A. 6 mm (0.24 in.) MAXIMUM

NOTE: X = ROD END THREAD DISTANCE 1. OUTER MAST
2. INNER MAST
1. ROD 3. CAPSCREWS
2. WRENCH FLAT 4. PLATE
3. NUTS 5. WEAR PLATE
4. ROD END 6. SHIM
Figure 77. Tilt Cylinder Adjustment Figure 78. Mast Support Pad Adjustment
68
4000 YRM 1647 Troubleshooting
Troubleshooting
INTRODUCTION
This troubleshooting list does not cover every possible problem. It is intended to help finding the cause of problem
in the mast system.
Before searching for the cause of a problem, make sure that all daily condition checks and fluid level checks have
been performed and that required repairs have been completed. See Periodoc Maintenance YRM.
If a problem occurs directly after a repair, verify if assembly instructions have been followed correctly. If a problem
has aggravated, verify if hydraulic oil cleanliness meets 21/17/13 according ISO 4406.
For diagnosing and verification of settings, make use of the Hydraulic User Interface ProgrammeYRM. See
Hydraulic Control SystemYRM.
Follow each step in the sequence shown in one of the three main search criteria:
• No Hydraulic Movement with Engine Running
• No Lowering Possible with Engine OFF
• Incorrect Movement
If this troubleshooting list did not help solving your problem, read the Description and Operation section in this
YRM to find further possible causes of failure.
NO HYDRAULIC MOVEMENT WITH ENGINE RUNNING
Initial Basic Check
Make sure the Transmission Calibration Switch is in the OFF position.
Turn the Key Switch to the ON position to verify that all warning lights and indicator lights on the instrument panel
will light up.
After two seconds all indicator lights must be OFF, except for the Wait to Start Light, Central Warning Lights and
Brake System Low Pressure Warning Light.
Start the engine after the Wait to Start Light is OFF.

• If any of the above steps fail, follow the steps mentioned under Electrical Supply
• If the Brake System Low Pressure Warning Light is still ON after 10 seconds, follow the steps mentioned
under Hydraulic Supply.
• If the Central Warning Lights are ON and a fault code is displayed, follow the steps mentioned under Fault
Code.
69
Troubleshooting 4000 YRM 1647
Electrical Supply
Determine which fuse and/or relay connect with the failed function and replace as necessary. See DiagramsYRM
and Fuses and Relays in Electrical System YRM.
• Investigate and resolve the root cause for the failed fuse and/or relay.
• Replace the failed fuse and/or relay.
Hydraulic Supply
Operate the steering system with the engine running. Hydraulic pump supply is sufficient when steering requires
normal effort.
• If abnormal effort is required, repair the steering system and/or investigate why hydraulic pump supply is
insufficient. See Steering SystemYRM.
Make sure that the Transmission Calibration Switch is in the OFF position.
Verify that the Operator Presence System (OPS) functions correctly.

• Hydraulic functions should operate normally when the operator is seated, the engine is running and the
transmission calibration switch is in the OFF position.
• Hydraulic functions should be interrupted when the operator is not seated.
• The OPS needs repair when hydraulic functions can only be operated with the hydraulic service switch in
the ON position.
• To repair the OPS, check functionality of OPS fuse, seat switch, seat belt switch, and operator presence
relay. Replace any failed OPS component.
Fault Code
Look up the fault code and determine the location of the indicated component on the truck. See DiagramsYRM
and Electrical SytemYRM.
• Check functionality of the component and repair as required.
If a fault code suggests checking a Directional Control Valve or an Actuation Valve, verify if partial or complete
replacement is required.
Move the spool by rotating the actuator axle about 15 degrees with a spanner.
• When the spool moves smoothly, replace the failed Electrical Actuation Module only.
• When the spool sticks, disassemble and clean the spool section.
• If components of the spool section are damaged after disassembly, replace the spool section.
70
4000 YRM 1647 Troubleshooting
NO LOWERING POSSIBLE WITH ENGINE OFF
Make sure the lift cylinders are extended and the lift chains carry at least the weight of the carriage.
• If the carriage is not installed, use the emergency lowering control valve to lower the mast.
Turn the key switch to the ON position.
Move the hoist lever into the lowering position.

• If fault code H2664 is displayed, resolve the open circuit or short circuit situation for the (emergency) Low-
ering Selector Valve [B].
Attach a pressure gauge to port MPLT.
Read the pressure gauge at port MPLT with the key switch in the ON position and the hoist lever in the lowering
position.
• If pressure is lower than 1 MPa, investigate proper functioning of the Pilot Supply Valve [F] and the Lower-
ing Selector Valve [B]. Repair or replace as necessary.
INCORRECT MOVEMENT
Irregular (shaking) Movement or Slight Carriage Movement When Starting Engine
De-aerate system by operating the affected function(s) several times.

• Activate for one second and reverse cycle. Repeat a few times.
• When the problem re-occurs, search for entry of air in pump suction line.
Unequal Movement of Left And Right Tilt Cylinder
Verify and correct tilt cylinder adjustment and condition of pivot points.
Establish and repair internal leaks in the tilt cylinders.
Verify and correct relief pressure setting of the individual tilt relief valves.
Insufficient Lifting Speed
Measure pilot pressure at port MPLT.

• If pressure is above 1 MPa, verify Hydraulic Flow Control Settings and correct as required. See Hydraulic
Control SystemYRM.
• If pressure is 1 MPa or less, inspect Pilot Supply Valve [F] and replace if found defective.
Verify pump performance.

• Measure Load Sense pressures. See Hydraulic SystemYRM.
• Inspect hydraulic pump and repair as required.
71
Troubleshooting 4000 YRM 1647
Insufficient Lifting Capacity
Verify correct relief valve pressures.

• Pressure at Port MP should reach 33 +/- 0.5 MPa for Full Flow Relief Valve [G].
• Pressure at Port MLS2 should reach 22.5 +/- 0.5 MPa for Load Sense Relief Valve [H].
• Replace relief valves as necessary.
Incorrect Lowering Speed
Verify Hydraulic Flow Control Settings and correct as required. See Hydraulic Control SystemYRM.
• Replace the Lowering Control Valve(s) at the lift cylinders if hydraulic controller settings appeared to be
correct.
Lift Cylinder Creep
Follow the instructions as described under Mast Vertical Creep.
Tilt Cylinder Creep
Follow the instructions as described under Mast Tilt Drift.
72
4000 YRM 1647 7/16 (2/16)(8/15)(7/15)(5/14)(11/13)

2-Stage Mast: Maintenance

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Maintenance

PART NO. 550088524 4000 YRM 1647

©2016 Yale Materials Handling Corp. i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (Continued)

This section is for the following models:

Series Code / Model Designation Reference Table

Series Code European Model Americas Model

Description And Operation

A relief valve is installed on lift trucks manufactured

The lift cylinders are supported at the base of the

The lift cylinders extend when hydraulic pressure ap-

1. PILOT OPERATED CHECK VALVE 3. PILOT SIDE

Figure 2. Pilot Operated Valves – Schematic

1. EMERGENCY LOWERING CONTROL VALVE

Figure 3. Emergency Lowering Control Valve - Location

The emergency lowering valve closes by turning the

The required time to maintain this low chain tension

Chain tension should not exceed the own weight of

Interruption of the oil film between pin and chain out-

Maintaining The Presence of Oil Requirements for Chain Lubricant

Load Rollers Bearing Blocks

Figure 8. Bearing Blocks and Load Rollers on

Figure 7. Mast Support Pads

CARRIAGE Standard Carriage with Hydraulic Fork

Standard Carriage with Manual Fork

The pin-type forks are kept in position by two locking

Figure 10. Standard Carriage with Hydraulic Fork

Figure 12. Integral Side Shift

Carriage Valve Fixed P & T systems require three header hoses,

Fixed P & T systems are applied when control valve

Figure 13. Flow Divider Port Connections - Schematic

Valve for Dual Function with Side Shift and

Fork positioning is controlled by simultaneous activa-

The direction of cylinder movement is controlled by

Side shifting is controlled by connecting the piston

Figure 15. Schematic for Dual Function Valve

Fixed Pressure and Tank System (Fixed P &

Fixed P & T systems use a directional control valve

Hydraulic operation of the directional valve is similar

The function of the two stage relief valve is to main-

1. HYDRAULIC FUNCTION 4. PILOT PRESSURE SUPPLY VALVE

Two different fork constructions are used, depending

SAFETY PROCEDURES WHEN WORKING Follow these procedures:

WHEN WORKING NEAR THE MAST ALWAYS:

1. Lower the mast and carriage completely. Push

2. If parts of the mast must be in raised position, in-

5. Turn engine OFF.

6. Turn the key switch to the ON position.

Remove and Replace

3. Place a pallet on a hydraulic jack or hand pallet

Table 1. Fork Sizes And Weights

Model Type Fork Size Shortest Shortest Longest Longest

9. Return fork pin to its assembled position and in-

10. Repeat Step 4 through Step 9 to remove remain-

2. Position fork guides in front of hoist chains.

3. Attach a lifting strap and lifting device to fork

NOTE: The fork pin weighs 55 kg (121.2 lb). The fork